Operation Manual: XAC20243 English

Operation Manual
A275-L59
XAC20243 English
Original Operation Manual
Chapter Document-ID
1 Introduction HZTL4005_EN_F
2 Safety HZTL4024_EN_D
3 Safety data sheet XAC20243
4 Product description HZTL4036_EN_N
ABB Turbocharging
Operating limits and replacement intervals
The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined
with the enginebuilder. This information is specific to the product.
Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre-
dictable component failures.
Operation Manual / 1 Introduction
Table of contents
Introduction
1 Introduction............................................................................................................ 2
1.1 Purpose of the manual.................................................................................................. 2
1.2 Symbols, definitions...................................................................................................... 3
1.3 Storage of new turbochargers and spare parts ...................................................... 5
1.4 Contact information...................................................................................................... 7
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
1 Introduction / 1.1 Purpose of the manual
1 Introduction
1.1 Purpose of the manual
Fig. 1: Serial number (01) on the rating plate
This Operation Manual belongs to the turbocharger with the identical serial number (01), see
chapter 3 (Safety data sheet) and the rating plate on the turbocharger.
Page 2 / 7
Operation Manual
The Operation Manual explains the turbocharger and contains instructions for safe opera-
tion.
The Operation Manual is a complement to and expansion of existing national regulations for
occupational safety, accident prevention and environmental protection.
Target group
The Operation Manual is aimed at engineers and trained mechanics responsible for the
proper operation of the engine and for the turbocharger connected to it.
Availability of the Operation Manual

The Operation Manual must be available where the turbocharger is used.
All persons operating or working on the turbocharger must have read and fully understood
the Operation Manual.
1 Introduction / 1.2 Symbols, definitions
1.2 Symbols, definitions
Symbols
The following symbols are used in this document:
u Indicates an action step.
1. Indicates a numbered action step.

→ Refers to a page number.
Definition of Note
NOTICE
Note
The note provides advice which facilitates the work.
Definition of mandatory signs

Mandatory signs show the protective equipment to be worn for a task. The mandatory signs
Page 3 / 7
are described in chapter Safety and must be complied with.
Definition of Caution / Warning

Caution and warning signs are described in chapter Safety.
ABB Turbo Systems

ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document.
Official service stations of ABB Turbo Systems

Official service stations are identified in this document as ABB Turbocharging Service Sta-
tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con-
tact information →7.
1 Introduction / 1.2 Symbols, definitions
Definition of pictograms
The following pictograms can occur in this document. These point out actions that must be
taken in accordance with the meaning of the relevant pictogram.
Pictogram Meaning Pictogram Meaning

Tighten with specified torque Affix
Tighten over specified tighten- Measure

ing angle
Hand-tight, tighten without Note
tools
Oil Visually inspect
Apply screw locking paste (e.g. Please note text for numbered
Loctite) work step
Apply high-temperature grease See document
Apply other paste in accord- Dispose of in an environmentally

ance with specifications compatible, professional way and
in compliance with locally applic-
Oil free, grease free and dry able regulations
Table 1: Definition of pictograms

Page 4 / 7
1 Introduction / 1.3 Storage of new turbochargers and spare parts
1.3 Storage of new turbochargers and spare parts
Storage of new turbochargers and spare parts for up to 6 months

New turbochargers and spare parts can be stored in their closed packages for 6 months
from the date of delivery without additional mothballing measures, indicated by the VCI la-
bel on the package.
Fig. 2: Volatile Corrosion Inhibitor (VCI)
Only dry rooms with 40...70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.
Storage of new turbochargers and spare parts for more than 6 months
WARNING
Health protection when handling VCI
VCI products are not hazardous in terms of the Ordinance on Hazardous
Page 5 / 7
Substances. Nevertheless, the following points must be observed when
handling VCI:
u Observe information in material safety data sheet
u Ensure proper space ventilation.
u Do not eat, drink or store food at the workplace while working with VCI.
u Clean hands and face after working with VCI.
u For more information, see www.branopac.com.
Wear safety gloves to protect against mechanical hazards.
Every 6 months, the following mothballing measures are required:

u Open package.
u Remove VCI corrosion protection emitter from package and replace with a new VCI corro-
sion protection emitter of the same kind. New VCI corrosion protection emitters can be
obtained from www.branopac.com.
u Old VCI corrosion protection emitters must be disposed of in an environmentally compat-
ible, professional way and in compliance with locally applicable regulations.
u Close package. The more tightly the package is sealed, the longer the protection dura-
tion.
1 Introduction / 1.3 Storage of new turbochargers and spare parts
Long-term storage of replacement turbochargers or spare parts

The turbochargers or cartridge groups will be prepared for long-term storage if requested in
the purchase order. The package is equipped with a hygrometer (see illustration).
Fig. 3: Package with hygrometer
Every 6 months, the following measures are required:

u Check the hygrometer (02) in the sight-glass. There is an opening (01) in the wooden
crate to enable you to perform this check. If the 70% indicator field has changed colour,
the maximum admissible atmospheric humidity has been exceeded. In this case, the tur-
bocharger or cartridge group must be checked and repackaged by an ABB Turbocharging
Service Station.
u Check the package for damage. If the package is damaged, the turbocharger or cartridge
group must be checked and repackaged by an ABB Turbocharging Service Station.
Page 6 / 7
After every 3 years, the following steps must be carried out by an ABB Turbocharging Service
Station:
¡ Checking the component
¡ Replacing the desiccant
¡ Repackaging the component.
NOTICE
Replacement components which are ready for operation
If the 70% field of the hygrometer (02) has not changed colour and the pack-
age is not damaged, the replacement turbocharger or replacement cartridge
group can be put into operation without previously having been checked by
an ABB Turbocharging Service Station.
Unpackaging replacement turbochargers or spare parts

Once the material has been unpackaged from the VCI package, the corrosion protection is
no longer effective.
To prevent condensation, the temperature of the package contents must be the same as the
ambient temperature.
1 Introduction / 1.4 Contact information
1.4 Contact information

Contact information for the ABB Turbocharging Service Stations is available online.
u Scan the QR code to access our website.
ABB Turbo Systems Ltd

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
Page 7 / 7
Operation Manual / 2 Safety / A100-L, A200-L
Table of contents
Safety
1 Safety ...................................................................................................................... 2
1.1 Introduction .................................................................................................................... 2
1.2 CE conformity ................................................................................................................. 2
1.3 Definition of mandatory signs .................................................................................... 3
1.4 Definition of safety instructions ................................................................................ 3
1.5 Intended use .................................................................................................................. 4
1.6 Warning plates on the turbocharger.......................................................................... 5
1.7 Turbocharger rating plate........................................................................................... 6
1.8 Periodic check of the pressure vessels...................................................................... 7
1.9 Lifting of loads .............................................................................................................. 8
1.10 Prerequisites for operation and maintenance........................................................ 9
1.11 Hazards during operation and maintenance ......................................................... 10
1.12 Safe operation .............................................................................................................. 12
1.13 Safe maintenance ........................................................................................................ 13
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
1 Safety / 1.1 Introduction
1 Safety
1.1 Introduction
Turbochargers manufactured by ABB reflect the state of the art. The respective safety and
health protection requirements are met. This ensures safe operation of the turbocharger.
Nevertheless, there may be some residual risks during operation of and work on the tur-
bocharger which:
¡ Are caused by the turbocharger itself or its accessories.
¡ Are caused by the operating equipment used or supplies and materials.
¡ Are a consequence of insufficient compliance with safety instructions.
¡ Are a consequence of insufficient or inappropriate performance of maintenance and in-
spection work.
The operating company is responsible for defining measures that regulate safe access to
and safe handling of the turbocharger.
All instructions contained in this chapter must be observed for safe and trouble-free opera-
tion of the turbocharger and during all work on the turbocharger.
Page 2 / 16
All further safety instructions contained and specifically identified in every chapter of this
manual (Definition of safety instructions →3) must also be observed.
1.2 CE conformity
Information
ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly com-
pleted machinery as defined by Article 2 g in this directive.
1 Safety / 1.3 Definition of mandatory signs
1.3 Definition of mandatory signs

To be worn at all times
Protective clothing Safety footwear to protect
against mechanical hazard and
risk of falling
Table 1: Personal protective equipment to be worn at all times
To be worn specific to the respective task

Safety glasses Safety goggles
Safety gloves to protect Respiratory mask to protect

against against
- Mechanical hazard - Dusts
- Chemical hazard - Gases
- Thermal hazard
Safety helmet Ear protection
Page 3 / 16
Table 2: Personal protective equipment to be worn specific to the respective task
1.4 Definition of safety instructions
WARNING
Definition of Warning
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word WARNING can lead to seri-
ous injuries to personnel and even to fatal accidents.
u Warning signs must always be observed.
CAUTION
Definition of Caution
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word CAUTION can lead to seri-
ous damage to engine or property with grave consequences.
u Caution signs must always be observed.
1 Safety / 1.5 Intended use
1.5 Intended use
Use on internal combustion engines in general

ABB turbochargers are intended for turbocharging internal combustion engines.
The A...-L turbochargers are designed for use on 2-stroke diesel engines.
The turbocharger supplies the engine with the air volume or air/gas mixture and the associ-
ated charging pressure required for operation.
The turbocharger is solely intended to be operated with a clockwise direction of rotation as
viewed from the turbine end.
The specific operating limits of the turbocharger were determined on the basis of informa-
tion from the enginebuilder about the intended use. These data are given on the rating
plate.
ABB accepts no liability and rejects all warranty claims for any non-intended uses.
WARNING
Unapproved operation
Any operation of the turbocharger outside of its operating limits can be haz-
Page 4 / 16
ardous to personnel.
u Only operate the turbocharger within the operating limits.
u Only trained personnel must operate the turbocharger.
The intended use of the turbocharger includes compliance with all regulations and condi-
tions. In particular, the following must be observed:
¡ Operation Manual
¡ Instructions of the enginebuilder
State of the art

The turbocharger is designed and manufactured according to the state of the art and is safe
to operate.
Perfect condition
The turbocharger must only be used when it is in a technically flawless condition and oper-
ated in compliance with its intended use.
ABB excludes any liability for damage resulting from unauthorized modifications to the tur-
bocharger or improper operation.
1 Safety / 1.6 Warning plates on the turbocharger
1.6 Warning plates on the turbocharger

Warning plates are attached to the turbocharger, which must be observed. The warning
plates must always be present in the intended locations and must be legible.
Fig. 1: Warning plate
If warning plates are not present in the intended locations or are not legible, they must be
replaced with new warning plates. The necessary information can be found in the Operation
Manual, Chapter 4 Product description.
Turbochargers supplied to the enginebuilder without insulation must be equipped later with
warning plates on the insulation. This is the responsibility of the enginebuilder.
Page 5 / 16
1 Safety / 1.7 Turbocharger rating plate
1.7 Turbocharger rating plate
Fig. 2: Rating plate
Operating limits
01 Turbocharger operating limits at engine overload (110 %).
In test rig operation only, unless otherwise agreed with the en-
ginebuilder.
Page 6 / 16
02 Turbocharger operating limits during operation
Recommended replacement intervals of turbocharger components

03 Replacement interval of plain bearings in 1000 h
04 Replacement interval of compressor in 1000 h
05 Replacement interval of turbine in 1000 h
Further data
06 Customer part number
07 Designation for special design
08 Weight of turbocharger in kg
09 Turbocharger type
10 Serial number
11 Year of construction of turbocharger
12 Manufacturing plant
1 Safety / 1.8 Periodic check of the pressure vessels
Explanations regarding the rating plate

The recommended replacement intervals and the corresponding operating limits are jointly
defined with the enginebuilder. This information is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the recommended
replacement intervals. In such cases ABB recommends contacting the nearest ABB Tur-
bocharging Service Station.
nMmax, tMmax normally apply only when running at overload (110%) during trials on the engine
test bed. These limit values can also be permitted during operation for special applications.
Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended replacement intervals increases the risk of unpredict-
able component failures.
Locations of the rating plates

The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product
description.
1.8 Periodic check of the pressure vessels
Page 7 / 16
The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are
so-called "simple pressure vessels".
¡ The locally applicable legal regulations regarding periodic checks of the pressure vessels
must be observed.
¡ The operating company is responsible for the safe operation of the pressure vessel.
WARNING
Danger due to pressure vessels
The operating company must make sure the pressure vessels are in proper
working condition and monitor them. Necessary repair or maintenance work
must be performed promptly, and the required safety measures must be
taken.
u Pressure equipment must not be operated if defects are present.
1 Safety / 1.9 Lifting of loads
1.9 Lifting of loads
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
u Loads must always be fastened to properly functional lifting gear with a
sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.
Wear safety helmet.

Page 8 / 16
Fig. 3: Attachment of loads on the crane hook
Fig. 4: Attachment angle
If there are two or more suspension points, the attachment angle of 45° must not be ex-
ceeded. This prevents excessive loading due to diagonal pull.
u Before looping around the components of the turbocharger, let them cool down (max-
imum 80 °C).
u Attach components of the turbocharger as described in the respective action steps.
u Use a suitable edge guard if there are sharp edges.
u The assembly devices must be completely screwed in and must not unscrew during use.
u Use assembly devices only for the described applications.
u Put down dismantled components of the turbocharger in such a way that they cannot tip
over.
1 Safety / 1.10 Prerequisites for operation and maintenance
1.10 Prerequisites for operation and maintenance
Responsibility of the operating company

In awareness of its responsibility, the operating company must ensure that only authorised
personnel work on the turbocharger, who:
¡ Are versed in the general and locally applicable regulations for occupational safety and
accident prevention
¡ Are equipped with the prescribed personal protective equipment
¡ Have read and understood the Operation Manual
¡ Have been instructed in the use of the turbocharger.
The safety-conscious work of the personnel and adherence to the Operation Manual must be
checked periodically.
Suitable working materials and personal protective equipment must be kept in a perfect
condition.
Only authorised personnel may remain in the vicinity of the turbocharger when the engine is
running.
Page 9 / 16
Competence of personnel
The turbocharger must only be operated and serviced by trained and authorised personnel.
Basic mechanical training is a prerequisite.
Modifications to the turbocharger

Modifications to the turbocharger must be approved by ABB Turbo Systems.
WARNING
Use original parts
Operation of the turbocharger with non-original parts can impair the safety
of the turbocharger and can cause serious damage to property and injury to
personnel.
u Only use original parts from ABB Turbo Systems.
Original parts and accessories are specially designed by ABB Turbo Systems for the ABB tur-
bochargers.
ABB accepts no liability for any damage resulting from the use of non-original parts and cor-
responding accessories.
1 Safety / 1.11 Hazards during operation and maintenance
1.11 Hazards during operation and maintenance
Noise hazards
The turbocharger's noise emission during operation is influenced by its installation and op-
erating conditions. A noise level exceeding 85 dB(A) is harmful.
WARNING
Danger due to noise
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).
Wear ear protection.
Hazards due to hot surfaces

Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hot
Page 10 / 16
during operation. The surface temperature depends on the efficacy of the existing insula-
tion. The temperature may rise to a level that can cause burns.
WARNING
Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause burns.
u Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the turbocharger to cool down before carrying out any work.
Wear safety gloves to protect against thermal hazards.
1 Safety / 1.11 Hazards during operation and maintenance
WARNING
Hot surfaces on the non-insulated turbocharger
Non-insulated turbochargers can cause serious injuries to personnel (burns).
The turbocharger is supplied with or without insulation in accordance with
the purchase order received from the enginebuilder. If supply is without in-
sulation, the enginebuilder is responsible for providing the turbocharger
with proper insulation and for providing protection against contact with hot
surfaces.
u Compliance with the instructions and specifications given by the en-
ginebuilder to protect against hot turbocharger surfaces is compulsory.
Hazards due to rotating parts
WARNING
Physical hazards
Contact with rotating parts can cause severe injury. The turbocharger must
Page 11 / 16
never be used without the filter silencer or the air suction branch. With the
engine stopped, the rotor can rotate due to the stack draught alone.
u Operate the turbocharger in compliance with the specifications.
u Secure the rotor against unintentional rotation during maintenance.
Hazards due to electrical installations (if present)
WARNING
Dangers during work on electrical installations
Electrical installations use voltages that can lead to severe injury to person-
nel or accidents resulting in fatalities.
At the same time, electrical or electronic components and parts can also be
damaged or destroyed.
u Only specially trained personnel should perform work on, or with, elec-
trical components.
u Observe national regulations.
1 Safety / 1.12 Safe operation
WARNING
Absence of grounding on electrical installations
Missing or incorrectly fitted grounding conductors can lead to severe injury
to personnel or accidents resulting in fatalities.
Electric shock or elevated electromagnetic disturbances can damage or des-
troy electrical and electronic components.
u Ground electrical installations properly with grounding conductors.
u Check the grounding connections on a regular basis and make sure they
are properly connected.
u Switch off the power supply before working on any electrical installations.
u After switching off the power supply, wait for 5 minutes to allow capacitors to discharge
and hot components to cool down.
u Ensure the power supply is switched off when working on electrical installations.
u Do not carry out any tests with regard to insulation resistance or voltage on the electrical
components.
1.12 Safe operation

Page 12 / 16
Mechanical hazards during operation

During standard operation, no mechanical hazards are caused by the turbocharger itself if it
has been properly installed.
Safety during commissioning and operation

u Visually inspect your working environment before starting work.
u Remove any obstacles and objects littering the workplace.
u Check all pipes to and from the turbocharger for damage and leaks before commission-
ing.
u Check turbocharger for recognisable damage or defects every 12 hours of operation or at
least once a day.
u Report any damage and any alterations of operational characteristics to the responsible
department immediately.
u In case of damage, take the turbocharger out of operation immediately and safeguard
against accidental/unauthorised use.
u When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at-
tention to the risks that may occur as a consequence of this energy input.
1 Safety / 1.13 Safe maintenance
1.13 Safe maintenance
Occupational safety
WARNING
Injuries to persons
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures or non-compliance with safety and health standards.
u When working on the turbocharger always wear safety footwear and pro-
tective clothing to protect against mechanical hazards.
u Keep personal protective equipment in perfect condition.
u Obey mandatory signs.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Only perform operations that are described in this manual.
u Only perform operations for which you have received instruction or train-
ing.
Page 13 / 16
Wear safety footwear to protect against mechanical hazard and risk of fall-
ing.
Wear protective clothing.
WARNING
Risk of falling
When working on the turbocharger, there is a risk of falling.
u Do not climb onto the turbocharger or onto attached parts and do not
use them as climbing aids.
u Use suitable climbing aids and working platforms for work above body
height.
u Comply with the general accident prevention regulations.
u Only perform work on the turbocharger when you are in a physically and psychologically
stable condition.
u Only work with suitable tools, equipment and appliances that function properly.
u Power tools must be grounded and cables must be undamaged.
u Keep the workplace clean; clear away any loose objects and obstacles on the floor.
u Keep the floor, equipment, and turbocharger clean.
u Have oil binding agents ready and provide or keep oil pans at hand.
u Clean up any spills.
u Have fire protection means and extinguishing agents available.
Welding work in the vicinity of the turbocharger

u When performing welding work in the vicinity of the turbocharger, always cover the filter
silencer to prevent the filter mat from being damaged.
u Keep flammable objects and substances out of the vicinity of flying sparks.
u Cover all connections on the turbocharger so that no foreign objects can enter the tur-
bocharger.
u Wear personal protective equipment (PPE) for welding operations.
Safety during cleaning

If cleaning agents or solvents are used for cleaning, the corresponding material safety data
sheet and the safety instructions in section Hazards due to operating materials and supplies
must be observed.
u Observe the material safety data sheet for the cleaning agent or solvent.
u Wear personal protective equipment (PPE) according to the material safety data sheet.
u Inspect the electric cables for abrasion and damage before and after your cleaning work.
Safety during disassembly, assembly, maintenance and repair

Page 14 / 16
u Observe the procedures for set-up, service and inspection work and the inspection inter-
vals.
u Inform the operating staff before starting any service or repair work. Make sure the en-
gine is not started while work is being conducted on the turbocharger.
u Before taking off any cover or removing any guard from the turbocharger, switch off the
engine and wait until the turbocharger has come to a standstill.
u Make sure that the oil supply is interrupted, especially with an external oil supply.
u Only restart the engine after all parts have been properly fitted again and oil supply is en-
sured.
CAUTION
Mechanical operations on the turbocharger
Components of the turbocharger can be damaged or destroyed as a result
of improper procedures.
u Only perform operations that are described in this manual.
u Only perform operations for which you have received instruction or train-
ing.
Safety when taking out of operation or preparing for mothballing

u Secure rotor against turning. The rotor can rotate due to the stack draught alone.
u Observe the material safety data sheet for the cleaning and mothballing agents.
u Wear personal protective equipment (PPE) according to the material safety data sheet.
Mechanical hazards when working on the turbocharger
WARNING
Physical hazards due to rotating parts
The rotor can rotate due to the stack draught alone. Contact with rotating
parts can cause severe injury.
u Secure rotor against turning.
WARNING
Mechanical hazards
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Ensure workplace safety.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have previously received instruc-
tion or training.
Page 15 / 16
Hazards due to operating materials and supplies
Operating materials and supplies are substances required for the operation of the tur-
bocharger or for the performance of maintenance work. Oils, greases, coolants, detergents
and solvents, acids and similar substances can be classified as hazardous substances.
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
WARNING
Danger of fire or explosion
Flammable and combustible operating materials and supplies can catch fire
or resulting vapours can lead to an explosion.
u Do not allow any exposed flame or ignition source during cleaning work.
u Carry out cleaning in the open or provide sufficient ventilation.
CAUTION
Environmental hazard
Improper handling of operating materials and supplies can lead to environ-
mental damage.
Page 16 / 16
Hazards due to the handling of insulation materials
WARNING
Danger from insulation materials
Dust or fibres from insulation materials can have adverse effects on the
health or cause irritations. Unsuitable and combustible insulation materials
are a fire hazard.
u Only use suitable and non-combustible insulation materials.
u Ensure good ventilation at the workplace.
u Avoid whirling up dust.
u Use dust-free tools and working methods.
u Remove package at the workplace only.
u Proceed with particular care when removing old insulation materials.
u Dispose of insulation materials properly and in an environmentally com-
patible manner in compliance with the legal regulations.
Wear a respiratory mask to protect against dusts.
Operation Manual / A275-L59 / Safety data sheet
Page 1 / 1
Safety data sheet
A275-L59 XAC20243
A275-L59 XAC20243
250 550
244 520
A275HZ00491 2019
6300 36 100 100
© Copyright 2019 ABB. All rights reserved. XAC20243 April 2019

Operation Manual / 4 Product description / A200-L
Table of contents
Product description
1 Introduction............................................................................................................ 3
1.1 Essential information.................................................................................................... 3
1.2 Registered trademarks ................................................................................................. 3
1.3 Related documents........................................................................................................ 3
1.4 Layout and function of the turbocharger ................................................................ 4
1.5 Warning plates on the turbocharger......................................................................... 6
1.6 Locations of the rating plates..................................................................................... 7
2 Removal and installation ...................................................................................... 8

2.1 Turbocharger weight ................................................................................................... 8
2.2 Removing the turbocharger........................................................................................ 8
2.3 Installing the turbocharger ........................................................................................ 10
3 Commissioning .................................................................................................... 13
3.1 Oil supply ....................................................................................................................... 13
3.2 Inspection procedures ................................................................................................ 13
3.3 Commissioning after taking out of operation....................................................... 15
4 Monitoring during operation.............................................................................. 16

4.1 Oil pressure, oil temperature..................................................................................... 16
4.2 Admissible air inlet temperature .............................................................................. 18
4.3 Turbocharger speed .................................................................................................... 18
4.4 Low pressure measurement at the filter silencer ................................................. 21
5 Operation and service ......................................................................................... 22

5.1 Noise emission ............................................................................................................. 22
5.2 Service work .................................................................................................................. 23
5.3 Expected replacement intervals ............................................................................... 27
5.4 Flexible turbocharger cut-out .................................................................................. 28
5.5 Stopping the engine................................................................................................... 29
6 Periodic maintenance.......................................................................................... 30
6.1 Foreword to maintenance......................................................................................... 30
6.2 Cleaning the filter silencer ......................................................................................... 31
6.3 Changing the filter strip on the filter silencer casing.......................................... 33
6.4 Cleaning the compressor during operation .......................................................... 35
6.5 Cleaning the turbine during operation................................................................... 39
6.6 Draining the gas outlet casing ................................................................................. 43
7 Troubleshooting................................................................................................... 44
7.1 Malfunctions when starting...................................................................................... 44
7.2 Malfunctions during operation ................................................................................ 45
© Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision N November 2018
Table of contents
7.3 Surging of the turbocharger..................................................................................... 47

7.4 Malfunctions when stopping.................................................................................... 48
7.5 Speed measurement system .................................................................................... 49
8 Disassembly and assembly................................................................................. 50

8.1 Introduction ................................................................................................................. 50
8.2 Weights of assemblies............................................................................................... 52
8.3 Disassembly and assembly of the filter silencer casing ..................................... 53
8.4 Dismantling the filter silencer .................................................................................. 58
8.5 Dismantling wall insert and diffuser....................................................................... 60
8.6 Axial clearance A prior to disassembly .................................................................. 64
8.7 Dismantling the insulation, the gas inlet casing and the nozzle ring (A275-L
and smaller)............................................................................................................................................. 65
8.8 Dismantling the gas inlet casing, nozzle ring (A280-L) ....................................... 69
8.9 Fitting gas inlet casing, nozzle ring, insulation (A275-L and smaller) .............. 73
8.10 Fitting the gas inlet casing, nozzle ring (A280-L).................................................. 77
8.11 Axial clearance A after assembly .............................................................................. 81
8.12 Fitting diffuser, wall insert ....................................................................................... 82
8.13 Fitting the filter silencer............................................................................................ 85
8.14 Table of tightening torques...................................................................................... 88
9 Taking a turbocharger out of operation........................................................... 90

9.1 Possible emergency repairs...................................................................................... 90
9.2 Taking defective turbochargers out of operation ................................................ 91
10 Mothballing the turbocharger............................................................................ 97

10.1 Taking the engine out of operation for up to 12 months ................................... 97
10.2 Taking the engine out of operation for more than 12 months .......................... 98
11 Disposing of turbocharger components .......................................................... 99
12 Spare parts ......................................................................................................... 100

12.1 Ordering spare parts................................................................................................ 100
12.2 View of turbocharger with part numbers ............................................................ 102
12.3 View of cartridge group with part numbers........................................................ 104
Figures................................................................................................................. 106
Tables .................................................................................................................. 108
1 Introduction / 1.1 Essential information
1 Introduction
1.1 Essential information
Design variants
This document is valid for different design variants of turbochargers. There may be sections
and descriptions of components that are not relevant for a specific turbocharger variant.
Please contact an ABB Turbocharging Service Station if you have any questions regarding a
design variant (see Contact information at www.abb.com/turbocharging).
Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understand-
ing. Differences in detail are therefore possible.
1.2 Registered trademarks
Page 3 / 108
The trademarks of outside companies are used in this document. These are marked with the
® symbol.
1.3 Related documents

Chapter Document number
Operation Manual / 1 Introduction HZTL4005
Operation Manual / 2 Safety HZTL4024
Operation Manual / 3 Safety data sheet *) Serial number of the turbocharger
Table 1: Related documents
*) This chapter is only available in serialised operation manuals.
1 Introduction / 1.4 Layout and function of the turbocharger
1.4 Layout and function of the turbocharger

Page 4 / 108
Fig. 1: Layout and function of the turbocharger
01 Filter silencer 08 Gas inlet casing

02 Thrust bearing 09 Bearing casing
03 Radial plain bearing 10 Diffuser
04 Radial plain bearing 11 Compressor wheel
05 Gas outlet casing 12 Compressor casing
06 Turbine wheel 13 Air-outlet silencer (option)
07 Nozzle ring
1 Introduction / 1.4 Layout and function of the turbocharger
Mode of operation
The turbocharger is a turbomachine and consists of the following main components:
¡ Turbine
¡ Compressor
These components are installed on a common shaft and form the rotor.
The exhaust gases of the internal combustion engine flow through the gas inlet casing (08)
and the nozzle ring (07) onto the turbine wheel (06). The turbine wheel uses the energy con-
tained in the exhaust gas to drive the rotor and, hence, the compressor wheel (11).
The exhaust gases then reach the atmosphere through the exhaust gas pipe connected to
the gas outlet casing (05).
The compressor wheel (11) sucks in fresh air and presses the compressed air into the cylin-
ders.
The air passes through the filter silencer (01) to the compressor wheel (11). The air then
flows through the diffuser (10) and exits the turbocharger through the compressor cas-
ing (12). An air outlet silencer (13) is optionally available. If installed, this will reduce the
amount of noise generated by the components at the outlet side after the compressor cas-
ing.
Page 5 / 108
The rotor runs in two radial plain bearings (03/04) which are located in the bearing cas-
ing (09) between the compressor and turbine. The axial thrust bearing (02) is located at the
compressor end.
The plain bearings are connected to a central lubricating oil duct which is normally supplied
by the lubricating oil circuit of the engine. The oil outlet always lies at the deepest point of
the bearing casing (09).
The turbocharger is equipped with an oil tank which is integrated in the bearing casing (9).
This oil tank supplies the bearings of the rotor with oil until standstill in the event that a mal-
function of the lubrication oil system causes an emergency stop of the engine.
1 Introduction / 1.5 Warning plates on the turbocharger
1.5 Warning plates on the turbocharger

Warning plates are affixed at the following locations:
Page 6 / 108
Fig. 2: Warning plate locations
If warning plates are not present in the designated locations or not readable, proceed as fol-
lows:
u Order new warning plates from ABB Turbocharging Service Stations.
u Remove any warning plates that have become unreadable.
u Clean and degrease the areas designated for the warning plates.
u Fit new warning plates and remove protective sheets.
Turbochargers supplied to the enginebuilder without insulation must be equipped later with
warning plates on the insulation. This is the responsibility of the enginebuilder.
1 Introduction / 1.6 Locations of the rating plates
1.6 Locations of the rating plates
Fig. 3: Locations of the rating plates
One rating plate (01) each is attached on the left and the right side of the turbocharger bear-
ing casing.
Page 7 / 108
2 Removal and installation / 2.1 Turbocharger weight
2 Removal and installation
2.1 Turbocharger weight

Lifting gear with a sufficient load limit must be used for transporting the turbocharger. The
weight specified below applies to the heaviest variant possible. Depending on the specifica-
tion, the weight specified on the rating plate may be lower than the standard value specified
here.
Weights of the complete turbocharger

Product Weight [kg]
A265-L 2600
A270-L 3800
A275-L 6300
A280-L 8700
Table 2: Weights A200-L with filter silencer
2.2 Removing the turbocharger

Page 8 / 108
WARNING
Risk of tipping
If the turbocharger is not sufficiently supported or not supported at all dur-
ing removal and installation, it may tip over and cause severe injury to per-
sonnel or accidents resulting in fatalities.
u Support the turbocharger at a suitable location.
u Secure with lifting gear wherever possible.
Wear safety helmet.
u Loosen cable to speed sensor.
u Disconnect all pipes according to the instructions of the enginebuilder.
u Check lifting gear.
u Fasten lifting gear on suspension eyes of the bearing casing and tauten.
2 Removal and installation / 2.2 Removing the turbocharger
Page 9 / 108
Fig. 4: Fitting lifting gear to turbocharger
u Loosen fixing screws on compressor-end and turbine-end foot.
u Lift turbocharger from engine and put down in a suitable location.
u Cover oil connections.
2 Removal and installation / 2.3 Installing the turbocharger
2.3 Installing the turbocharger
2.3.1 Placing the turbocharger on the bracket

Page 10 / 108
Fig. 5: Placing the turbocharger on the bracket
u Remove covers from the oil connections.
u Align turbocharger and place on engine bracket.
u Tighten fixing screws (Steps for fastening the turbocharger →11); while doing this, only
slightly loosen the lifting gear.
u Remove lifting gear from suspension eyes of the bearing casing.
u Connect cable to speed sensor.
u Connect all gas, air and oil pipes.
2.3.2 Steps for fastening the turbocharger
General information
Subject Requirement / Information
Turbocharger fixing elements ISO property class ≥ 8.8
Washers Hardened, thickness ≥ 15 % nominal thread dia-
meter
Dimension a (compressor end) a = height of turbocharger foot a
Dimension a (turbine end) a = height of turbocharger foot F + spacer sleeve D
Value b Hole in bracket
Dimension c Thread length, ≥ 1.5 x nominal thread diameter
Coefficient of friction 0.12 (lightly oiled)
Table 3: General information about fastening the turbocharger
Compressor-end foot
Page 11 / 108
Fig. 6: Compressor-end foot
u Tighten the foot fixing screws or nuts diagonally according to the selected tightening
method.
Turbine-end foot
Fig. 7: Turbine-end foot
u Tighten the foot fixing screws or nuts according to the selected tightening method.
Torque-controlled tightening
Product Thread size Height a of foot Tightening torque
[mm] [Nm]
A265-L M22 86 440
A270-L M27 100 830
A275-L M30 120 1100
A280-L M33 136 1500
Table 4: Tightening torques (foot screws)
Angle-controlled tightening
Product Thread size Height a of Pre-tightening Tightening Additional tightening
foot torque angle for angle for every 10 mm of
[mm] [Nm] height a additional screw length
[DEG] b
[DEG]
A265-L M22 86 120 30 3.7
A270-L M27 100 220 30 3.1
A275-L M30 120 300 30 2.6
A280-L M33 136 400 35 2.6
Table 5: Tightening angle (foot screws)
Page 12 / 108
Pinning of turbocharger feet with positioning pins

If the turbocharger is pinned at its feet, one pin hole per foot must be used.
3 Commissioning / 3.1 Oil supply
3 Commissioning
3.1 Oil supply
3.1.1 Introduction
In all operating states, a functioning and carefully executed oil supply is an important pre-
requisite for trouble-free operation of the turbocharger.
The lubrication of the turbocharger is usually carried out with oil from the engine oil circula-
tion.
u Comply with the enginebuilder's specifications regarding the selection of lubricating oil
and the oil change intervals.
For more information on the oil supply, refer to Chapter Oil pressure, oil temperature →16.
3.1.2 Oil filtering

Filtering of the lubricating oil with a filter mesh width of ≤ 0.050 mm is sufficient for the tur-
Page 13 / 108
bocharger.
3.1.3 Oil pressure

Comply precisely with the oil pressure before the turbocharger for trouble-free operation.
If the oil pressure at the inlet of the turbocharger is too high, it can be reduced with a
throttle valve. The throttle valve is normally already fitted on the turbocharger and has been
correctly set by the enginebuilder. This takes place either during the trial run on the engine
test bed or during the trial phase of the system.
If the oil pressure values are outside the admissible range during normal operation, you
must contact the enginebuilder.
3.2 Inspection procedures
3.2.1 Introduction
Inspection procedures include preventative visual controls, monitoring and measuring work
before and during commissioning. Inspection procedures enable changes to the turbochar-
ger to be detected. Machine damage can be prevented.
3 Commissioning / 3.2 Inspection procedures
3.2.2 Checks before commissioning
Filter mat (if available)

u Check for damage and contamination.
Lubricating system
CAUTION
Contaminated oil
Serious damage to engine or property can be caused by dirt and solid ma-
terial particles in the oil.
u For the initial commissioning phase and after all service work, flush the
complete lubricating system with warm oil.
u Use special running-in filters when running in the engine and after all ser-
vice work on the lubricating system.
u Check that the oil filter is clean before commissioning.
u Check the oil pressure in the oil supply pipes.

Page 14 / 108
Warning plates
u Check whether warning plates are present and legible.
u Check whether the protective sheets have been removed from new warning plates.
3.2.3 Checks after commissioning (engine in idle mode)
Lubricating system
u Check the oil pressure in the oil supply pipes.
u Check oil inlet temperature.
The admissible values are specified in section Oil supply.
Gas, air and oil pipes

u After starting the engine, check all gas, air and oil pipes for leaks.
3 Commissioning / 3.3 Commissioning after taking out of operation
3.2.4 Checks when starting up the engine

u Measure speed, oil pressure and charging pressure at various engine performances.
u Measure the exhaust gas temperature before and after the turbine.
u Measure the air temperature before and after the compressor.
u Compare the measured values with the values of the acceptance report. Different operat-
ing conditions indicate a malfunction (see Chapter Troubleshooting →44).
Escape of oily fluids

Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids
during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak.
u If there is a leak, contact an ABB Turbocharging Service Station.
3.3 Commissioning after taking out of operation
If present
Page 15 / 108
u Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the
gas outlet.
General
u Check the exhaust gas pipe before and after the turbine for combustion residues or wa-
ter residues and clean it. Remove any foreign objects that may be present.
u Check and clean filter silencer or air supply line, and remove any foreign objects that may
be present.
u Put engine-side oil circulation to the turbocharger into operation.
u Prepare the turbocharger for operation (see Checks before commissioning →14).
u The turbocharger is now ready for operation.
4 Monitoring during operation / 4.1 Oil pressure, oil temperature
4 Monitoring during operation
4.1 Oil pressure, oil temperature
Lubricating oil pressure before turbocharger
CAUTION
Assuring lubricating oil pressure
Serious damage to the engine or property can result from a missing or insuf-
ficient lubricating oil supply.
u The lubricating oil pressure must be monitored during operation and the
necessary pressure assured at the oil inlet.
Status for operation Oil pressure before tur-

bocharger
[bar]
Admissible, for normal operation, 0.8 … 2.5
with an oil temperature range at the inlet of 30 ... 70 °C
Page 16 / 108
Admissible, for normal operation, 0.8 … 2.0

with an oil temperature range at the inlet of 70 ... 85 °C
Admissible, during engine warm-up 0.8 … 4.0
Temporarily admissible ( < 1 h ) → alarm 0.6 … 0.8
Not admissible → emergency stop 0.0 … 0.6
Admissible, during pre-lubrication and post-lubrication (engine 0.2 … 0.6
stopped)
Table 6: Lubricating oil pressure, oil inlet
Lubricating oil temperature at the inlet
CAUTION
Machine damage
If the oil temperature at the oil inlet exceeds the admissible range, this may
lead to engine damage.
u Observe oil temperature at the oil inlet according to the following table.
Status for operation Oil temperature at the inlet

Toil,inlet [°C]
Admissible 30 … 85
Temporarily admissible ( < 1 h ) → alarm > 85
Not admissible → stop engine > 90
Not admissible → do not start engine (before start: preheat < 30
oil)
Table 7: Lubricating oil temperature at the inlet
4 Monitoring during operation / 4.1 Oil pressure, oil temperature
Lubricating oil temperature at the outlet

The oil temperature at the outlet is mainly dependant on:
¡ Lubricating oil temperature and pressure at the oil inlet
¡ Engine load and turbocharger speed
¡ Exhaust gas temperature
The maximum admissible oil temperature at the outlet is listed in the following table. The
specified oil outlet temperature is to be considered as alarm value for the turbocharger op-
eration and must be monitored according to the current regulations.
Status for operation Oil temperature at the inlet Oil temperature at the outlet
Toil,inlet [°C] Toil,outlet [°C]
Admissible 45 ≤ 110
Admissible 85 ≤ 130
Temporarily admissible → alarm 45 > 110
Temporarily admissible → alarm 85 > 130
Not admissible → stop engine 45 > 120
Not admissible → stop engine 85 > 140
Table 8: Lubricating oil temperature at the outlet
Page 17 / 108
If the turbocharger was operated for a longer period of time outside of the admissible
range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Tur-
4.1.1 Pre-lubrication and post-lubrication
CAUTION
Pre-lubrication
Serious damage to engine or property can result if the turbocharger is not
supplied with oil from the first moment after starting the engine.
u Activate the pre-lubrication device each time before starting the engine.
The pre-lubrication time is at least 5 minutes.
The post-lubrication time is at least 10 minutes.

If the engine is operated for 5 to 10 minutes in idle mode before stopping, no additional
post-lubrication is required.
4 Monitoring during operation / 4.2 Admissible air inlet temperature
4.2 Admissible air inlet temperature

The permitted air inlet temperature must be between -40C°… +45C°.
4.3 Turbocharger speed
4.3.1 Introduction
The speed of the turbocharger must be permanently monitored.
CAUTION
Do not use cables as a climbing aid
If you pull the speed measurement cables too hard, contacts can be pulled
out.
u Do not tension the speed measurement cables.
4.3.2 Layout and overview

Page 18 / 108
Fig. 8: Layout and overview of the speed measurement system
86505 Speed sensor 86528 Tachometer

86506 O-ring 42047 Screw plug
86515 Cable connector 32109 Sealing disc with cams
86526 F/I converter *) Alternative mounting position for speed
sensor
or for the second speed sensor
4 Monitoring during operation / 4.3 Turbocharger speed
4.3.3 Speed differences with several turbochargers per engine

The speeds of all turbochargers on an engine vary only slightly from each other in standard
operation.
The difference between the highest and the lowest turbocharger speed must not be more
than 3 %, relative to the speed limit nBmax.
If this permissible range of difference is exceeded, the following steps must be carried out:
u Reduce the engine performance immediately to the point at which the maximum tur-
bocharger speed does not exceed 70 % of nBmax.
u If the engine cannot be stopped, it can continue to be driven at this reduced engine load
or turbocharger speed.
u If a turbocharger surges continuously, the engine performance must be reduced further.
u Measure the temperatures in the air lines and gas piping from and to the turbochargers
and compare with normal values. If clear deviations of temperature are found, the nearest
ABB Turbocharging Service Station has to be contacted.
u Check the pressure loss of the alternative air inlet and compare it with normal values.
If the engine can be stopped temporarily:

u Inspect air lines, gas piping and the turbochargers and remedy any malfunctions.
Page 19 / 108
u In any case, contacting the nearest ABB Turbocharging Service Station is recommended.
4 Monitoring during operation / 4.3 Turbocharger speed
4.3.4 Replacing the speed sensor
WARNING
Hot cable connector and hot speed sensor
Danger of burns. The cable connector and speed sensor can reach temperat-
ures in excess of 100 °C during operation.
u When disassembling the cable connector and speed sensor, wear safety
gloves.
u The speed sensor is designed with a sealing lip and does not require a sealing disc for as-
sembly.
Page 20 / 108
Fig. 9: Replacing the speed sensor
Part number A265-L A270-L A275-L A280-L

86505 M18x1.5 M18x1.5 M18x1.5 M27x2
150 Nm 150 Nm 150 Nm 320 Nm
Table 9: Tightening torques (86505)
u Reduce the engine performance to idling and then stop the engine. Pay attention to post-
lubrication (Stopping the engine →29).
u Switch off the lubricating oil supply to the turbocharger.
u Disconnect the cable connector from the speed sensor.
u Unscrew the defective speed sensor.
u Screw in new speed sensor to the stop.
u Connect cable connector (86515) with the speed sensor (86505)
u Switch on lubricating oil supply to the turbocharger.
4 Monitoring during operation / 4.4 Low pressure measurement at
the filter silencer
4.3.5 Malfunction of the speed measurement system

The possible reasons for malfunction of the speed measuring system are described in
chapter Troubleshooting.
4.4 Low pressure measurement at the filter silencer
4.4.1 Introduction
The low pressure measurement with a U-tube manometer is used for the following pur-
poses:
¡ During acceptance test of the engine: Measurement of the correction factor for the cal-
culation of the turbocharger efficiency
¡ When using a filter mat: An increased pressure loss indicates an increase in the fouling of
the filter material.
4.4.2 U-tube manometer at the filter silencer
Page 21 / 108
Fig. 10: U-tube manometer at the filter silencer
81000 Filter silencer

81050 U-tube manometer
A [mm H2O] Pressure loss / pressure difference
If the turbocharger is operated at maximum engine power and pressure loss (A) reaches the
value of 200 mm H2O:
u Clean filter mat.
Reading of pressure loss

For simple reading of the pressure loss (A), the dipstick at the U-tube manometer can be
pulled out to the level of the lower water level. Better readability of the U-tube manometer
can be achieved by filling with slightly coloured water.
u Colour the water with food colouring or ink.
5 Operation and service / 5.1 Noise emission
5 Operation and service
5.1 Noise emission
WARNING
Danger due to noise
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).
The emission sound pressure level (A-weighted) is measured at a distance of 1 meter from
the turbocharger.
The highest value of the emission sound pressure level1) reaches a maximum of 105 dB(A)
near the filter silencer. The following prerequisites must be fulfilled with regard to the tur-
Page 22 / 108
bocharger to observe this limit value:

¡ Air-inlet system has been fitted
¡ All standard, noise-reducing measures2) have been fitted
¡ Bellows at the air outlet has been acoustically insulated by the enginebuilder (see Fig. 11:
Noise insulation, bellows →23).
The enginebuilder is responsible for insulating the charge air/scavenging air line and the
charge air cooler.
1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :
A-weighted emission sound pressure level
2) The enginebuilder must provide acoustically equivalent measures in case of deviating in-
sulation versions
5 Operation and service / 5.2 Service work
Suggestion for noise insulation, bellows
Fig. 11: Noise insulation, bellows
01 Compressor casing
02 Bellows
Page 23 / 108
03 Charge air duct / scavenging air duct
04 Insulation cushion
05 Insulation mat (at least 15 mm)
06 Sheet metal cover
5.2 Service work

Service work includes visual controls, monitoring, measuring and inspection as well as func-
tional checks. Service work enables the detection and rectification of changes to the tur-
bocharger and ensures full operability of the turbocharger.
CAUTION
Service intervals
Any service work on the turbocharger that is omitted or performed too late
can cause excessive contamination, wear and operating failures.
u Carry out the service work at the specified time intervals.
CAUTION
Shortened service intervals
Exceptional stresses such as several starts/stops per day, harsh environ-
mental conditions, poor fuel quality or high system vibrations can lead to
untimely machine damage even if the prescribed service intervals are ob-
served.
u Agree on a shortened service interval with ABB Turbo Systems.
To prevent machine damage caused by ageing and downtime, we recommend having an in-
spection carried out by an ABB Turbocharging Service Station no later than 5 years after the
last service.
5.2.1 Service work every 25 … 50 hours
CAUTION
Unknown operational changes
Impairment to the degree of a possible operating failure can be the con-
sequence.
u Have any unknown causes clarified by an ABB Turbocharging Service Sta-
tion.
u Visual check for air, exhaust gas, water and oil leaks.
u Record operating data and enter in the engine logbook.
u In case of deviations, determine the cause.
5.2.2 Service work at 100 hours after commissioning

Page 24 / 108
u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-
gine is stopped.
5.2.3 Service work on turbocharger every 18000 hours

It is recommended to have this service work and these checks carried out by an ABB Tur-
bocharging Service Station. Damaged and worn out parts must be replaced with original
ABB parts.
Take note of correct customer spare part set (see chapter Ordering spare parts →100).
u Remove and clean the filter silencer and check for damage.
u Dismantle the wall insert.
u Check axial clearance A.
u Clean compressor wheel, diffuser, wall insert and compressor casing and check for dam-
age.
u Check the nozzle ring, turbine diffuser and turbine blades for any possible contamination,
damage or wear using a borescope.
This checking can also be carried out after disassembling the gas inlet casing.
u Fit the wall insert.
u Install the filter silencer.
5.2.4 Service work on turbocharger every 36000 hours

Service work on the rotor and bearing parts must be carried out by an ABB Turbocharging
Service Station. Damaged and worn out parts must be replaced with original ABB parts.
Take note of correct customer spare part set (see chapter Ordering spare parts →100).
u Remove the filter silencer.
u Clean filter silencer and check for damage.
u Dismantle the wall insert.
u Check axial clearance A.
u Clean wall insert, diffuser and compressor casing and check for damage.
u Remove the gas inlet casing and dismantle the nozzle ring and cover ring.
u Clean the nozzle ring and cover ring and check for damage.
u Dismantle, inspect and balance the rotor.
u Replace the plain bearing
5.2.5 Service work according to instructions of enginebuilder

u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-
gine is stopped.
Page 25 / 108
5.2.6 Entries in the engine logbook

The monitoring of the engine system enables conclusions to be drawn on the behaviour of
the turbocharger.
The following operating data and measured values must be entered regularly into the engine
logbook of the enginebuilder:
¡ Performance and speed of the engine
¡ Speed of the turbocharger
¡ Air intake temperature
¡ Exhaust gas temperature before and after the turbine
¡ Pressure of the charge air
¡ Pressure loss in the charge air cooler
¡ Lubricating oil pressure and lubricating oil temperature
¡ Pressure loss in the filter silencer
¡ Air temperature after the charge air cooler
If present:
Page 26 / 108
¡ Air temperature after the compressor
5 Operation and service / 5.3 Expected replacement intervals
5.3 Expected replacement intervals

During the prescribed periodic service work, the individual parts are examined for wear and
replaced if necessary.
Expected replacement intervals [h]

Turbocharger part Operation with HFO *)
Gas inlet casing 50000 … 100000
Gas outlet casing 50000 … 100000
Nozzle ring 35000 … 50000
Cover ring 25000 … 50000
Other casings 100000
Table 10: Expected replacement intervals for turbocharger parts
*) HFO = Heavy Fuel Oil
Recommended replacement intervals [h]

Rotor components See rating plate data
Bearings See rating plate data
Page 27 / 108
Table 11: Recommended replacement intervals for turbocharger parts
The specified values are guideline values and not guaranteed values, see Influencing para-
meters.
5 Operation and service / 5.4 Flexible turbocharger cut-out
Influencing parameters
The specified values are guideline values and are not guaranteed. The actual values can devi-
ate considerably from the guideline values, for example, due to the following influences:
¡ Fuel quality and fuel treatment
¡ Load profile (thermal cycling, also number of starts/stops, emergency shutdowns, oper-
ating point)
¡ Gas inlet temperature
¡ Frequency and execution of cleaning process during operation
¡ Turbocharger specification.
¡ System-specific operating conditions (combustion quality, exhaust gas composition)
For bearing parts

¡ Lubricating oil quality (oil filtering, oil condition, oil monitoring)
¡ Load profile (speed, pressure conditions, temperature)
¡ Number of starts/stops
¡ Unbalance of the rotor (degree of contamination).
Page 28 / 108
5.4 Flexible turbocharger cut-out

If the load is low, an engine which is charged by multiple turbochargers can be operated with
one turbocharger switched off. The flexible switch-on or switch-off of a turbocharger is re-
ferred to as a "flexible turbocharger cut-out". In flexible systems, slide valves or flaps are in-
stalled by the enginebuilder before the gas inlet and after the air outlet of the turbocharger.
Depending on the version of the system, the turbocharger can be switched off or on manu-
ally or automatically. In all cases, you must observe the enginebuilder's recommendations.
The lubricating oil supply of the switched-off turbocharger must not be switched off due to
the engine vibrations. To ensure that there are no oil or gas leaks on the switched off tur-
bocharger, it must be supplied with external sealing air.
The turbocharger may only be switched on or off while the engine is stopped or in idle mode.
CAUTION
Flexible turbocharger cut out
Improper manipulations can result in inadmissible turbocharger speeds
which can lead to serious damage to property with grave consequences.
u The air outlet flap and gas inlet flap must be completely open during nor-
mal operation.
u During cut out operation, the air outlet flap and gas inlet flap must be
completely closed.
5 Operation and service / 5.5 Stopping the engine
CAUTION
Manual switching of the flaps
If the gas inlet flap is opened during cut-out operation or the air-outlet flap
is closed during normal operation, this causes very high turbocharger
speeds. These can result in damage with serious consequences or even a
total loss of the turbocharger.
u Never open the gas inlet flap during cut-out operation.
u Never close the air-outlet flap during normal operation.
CAUTION
Automatic switching of the flaps
During automatic flap control, there is a risk of the turbocharger rotating
opposite the intended direction of rotation if the air-outlet flap is open fur-
ther than the gas inlet flap during the switching process. This can lead to
damage on the turbocharger.
u The turbocharger should only be switched on or off below charging pres-
sures of 0.3 bar.
u Close the compressor outlet flap just before the gas inlet flap.
Page 29 / 108
NOTICE
Contamination with closed flaps
To limit the deposits of dirt when operating with closed flaps, we recom-
mend you open them at least every 500 hours of operation.
5.5 Stopping the engine

u Observe the instructions regarding post-lubrication (Pre-lubrication and post-lubrication
→17)
u Stop the engine.
6 Periodic maintenance / 6.1 Foreword to maintenance
6 Periodic maintenance
6.1 Foreword to maintenance

Maintenance work includes regular visual controls and cleaning operations which are inten-
ded to ensure the trouble-free functioning of the turbocharger.
Described maintenance points:
¡ Filter silencer
¡ Compressor
¡ Turbine and nozzle ring
Page 30 / 108
6 Periodic maintenance / 6.2 Cleaning the filter silencer
6.2 Cleaning the filter silencer
Filter silencer with tension band
Page 31 / 108
Fig. 12: Layout and overview of filter silencer
81126 Lock 81266 Cover grid

81135 Body of filter silencer 81268 Connecting strip
81136 Absorption segment 81270 Tension band
81137 Sheet-metal covering 81271 Lock
81265 Filter ring (if present) 81400 Water connection
E Insert unit (absorption segment / sheet-metal covering fitted)
6 Periodic maintenance / 6.2 Cleaning the filter silencer
Cleaning the filter ring (if present)

u Remove filter ring (81265).
u Clean filter ring (81265) as required or every 500 hours of operation and replace after the
fifth cleaning process at the latest.
Contamination of the filter ring depends on the degree of purity of the sucked-in air.
u Rinse the filter ring (81265) with water and mild detergent or, in the case of heavy con-
tamination, soak and carefully push through. Rinse in cold water. Avoid high mechanical
loads (water jet).
u Let the filter ring dry completely before assembling.
u Dirty water and mild detergent must be disposed of in compliance with locally applicable
regulations.
Cleaning the absorption segments

u Loosen the tension bands (81270) at the locks (81271) and remove them along with the
cover grid (81266) and connecting strips (81268) (see Fig. 12: Layout and overview of fil-
ter silencer →31).
u Pull out insert units (E).
u Bend up the sheet-metal coverings (81137) and remove the absorption segments (81136).

Page 32 / 108
u Clean the absorption segments (81136).

When cleaning, note that the absorption segments may only be cleaned lightly with pres-
surized air, with a soft brush or a moist cleaning cloth. Otherwise there is a danger of
damage or changing of the shape.
u Replace heavily contaminated absorption segments (81136) and any damaged connecting
strips (81268) with original parts from ABB.
Fitting the filter silencer

u Insert the absorption segments (81136) into the sheet-metal coverings (81137).
u Bend the sheet-metal coverings (81137) back into the original shape.
u Insert the insert units (E) into the slotted guides in the filter silencer body (81135).
u Fit the cover grid (81266) and connecting strips (81268) on the filter silencer body (81135).
u Guide the tension bands (81270) through the eyelets of the connecting strips (81268).
u Tighten the tension bands (81270) at the locks (81271).
u Any damaged tension bands must be replaced.
u Fit filter ring (81265), if present.
6 Periodic maintenance / 6.3 Changing the filter strip on the filter si-
lencer casing
6.3 Changing the filter strip on the filter silencer

casing
This chapter applies only to turbochargers with filter silencer casing. The filter ring (81265) is
replaced with the filter silencer installed.
Page 33 / 108
Fig. 13: Dismantling filter ring circumferential part
u Dismantle circumferential part (9).
Fig. 14: Opening filter ring lock
u Open the lock of the filter ring (81265).
6 Periodic maintenance / 6.3 Changing the filter strip on the filter si-
lencer casing
Fig. 15: Attaching new filter ring
u Attach the new filter ring (81265) on the filter ring to be replaced so they overlap.
Page 34 / 108
Fig. 16: Fitting new filter ring
u Pull on the old filter ring until the new filter ring is completely wrapped around the filter
silencer.
u Undo the connection between the new and the old filter ring.
u Fasten the newly installed filter ring (81265), then fit circumferential part (9).
6 Periodic maintenance / 6.4 Cleaning the compressor during opera-
tion
6.4 Cleaning the compressor during operation
6.4.1 Introduction
Approval by enginebuilder
The following instructions for wet cleaning only apply to cleaning with pure water and under
the precondition that the enginebuilder approves the process.
The contamination of the compressor stage (compressor wheel, wall insert and diffuser) de-
pends on the degree of purity of the air that is sucked in.
Deposits can form in the flow channels if salt, oil mist or dust are sucked in with the air.
Consequences of contamination:
¡ Impaired compressor efficiency
¡ Higher exhaust gas temperatures
¡ Increased fuel consumption
¡ Increased rotor unbalance
Page 35 / 108
Periodic cleaning of the compressor during operation prevents or delays any major increase
in contamination. But it never replaces the regular service work where the turbocharger is
completely dismantled and the compressor is mechanically cleaned.
Cleaning interval
The interval between the cleaning cycles depends greatly on the operating conditions.
Cleaning should normally take place about every 50 hours of operation.
If the specified cleaning intervals are incompatible with operation of the engine, contact
ABB Turbo Systems.
Cleaning method and operating state

The compressor is cleaned during operation using the wet cleaning method. The cleaning
method is tested and approved by ABB Turbo Systems.
When undertaking wet cleaning, the following operating state must be ensured:
¡ engine load between 25 … 85 %.
¡ If the engine compartment temperature is below 0°C when wet cleaning the compressor,
precautionary measures should be taken to prevent ice from forming.
tion
Principle of wet cleaning
CAUTION
Corrosion and deposits when cleaning
Salt water and cooling water treatment substances damage and adversely
affect turbocharger parts.
u Never use salt water, but only pure water for cleaning.
To clean the compressor stage during operation, water is injected upstream of the com-
pressor wheel.
The water does not act as a solvent. The coating is removed by the mechanical action of the
impacting droplets. The procedure is perfectly suitable, provided that the contamination
has not progressed too far.
Cleaning several turbochargers

If several turbochargers are installed on an engine, it is recommended to clean one com-
pressor after the other.
CAUTION
Page 36 / 108
Volume of water for cleaning the compressor

Uncontrolled volumes of water can damage the turbocharger and the en-
gine.
u Do not guide water pipes to the filler openings.
tion
6.4.2 Wet cleaning of compressor
WARNING
Damage to hearing due to high noise level
Removing the screw plug (81126) from the filler orifice (B) may result in a
high level of noise. Carrying out wet cleaning on the compressor without ear
protection may lead to serious hearing damage.
u Always wear ear protection when carrying out wet cleaning on the com-
pressor.
Page 37 / 108
Fig. 17: Overview of wet cleaning of compressor
81000 Filter silencer A Can

81126 Lock B Filler opening
u Remove insulation from flange of filter silencer (81000) (if present).
u Unscrew lock (81126).
u Measure volume of water according to the following table.
u Pour this water into a clean can (A).
u Carefully pour this water into the filling orifice (B) from the can.
u Screw in lock and hand-tighten.
u Fit insulation to flange of filter silencer (if present).
u After cleaning, allow the engine to continue to run for at least 5 minutes under normal
load.
tion
Repeating the cleaning

If the cleaning is still unsuccessful after three processes, it is recommended to have the tur-
bocharger checked and cleaned by an ABB Turbocharging Service Station if the engine val-
ues are unsatisfactory.
Volume of water per cleaning process

Product Quantity [dm3]
A265-L 2.0
A270-L 2.0
A275-L 3.0
A280-L 3.0
Table 12: Volume of water per cleaning process
The filling time is 4 ... 15 seconds.
Checking the filter plug

The filter plug only needs to be checked in the turbocharger version with a cast filter silen-
cer. See chapter Design variants →58.
Page 38 / 108
Fig. 18: Filter plug view
Disassembly and checking of the filter plug (81125) is required if, 20 seconds after the clean-
ing process, water is still visible in filler opening B.
u Loosen and remove the filter plug (81125) with box spanner.
u Clean the drill holes of the plug.
u Fit filter plug (81125).

81125 G1/2" G1/2" G1/2" G1/2"
45 Nm 45 Nm 45 Nm 45 Nm
Table 13: Tightening torques (81125)
6 Periodic maintenance / 6.5 Cleaning the turbine during operation
6.5 Cleaning the turbine during operation
6.5.1 Introduction
Combustion of heavy fuel oil in diesel engines causes contamination of the turbine blades
and nozzle rings of the turbochargers.
Contamination increases with time, which is why regular and properly carried out cleaning
operations are important to remove any deposits.
Contaminated turbine components lead to a reduction in the turbocharger efficiency. Fur-
thermore, the exhaust gas temperature after the cylinders can rise and the charging pres-
sure in the air receiver can drop.
Contamination of the turbine also leads to rotor unbalance. A very high level of contamina-
tion can lead to intolerably high rotor unbalance.
Despite periodic cleaning during operation, experience shows that overhauls during which
the turbine and nozzle ring (or VTG) are mechanically cleaned cannot be omitted.
Cleaning method
The turbine and the nozzle ring are cleaned during operation using the dry cleaning method.
This cleaning method is tested and approved by ABB Turbo Systems.
Page 39 / 108
Interval for dry cleaning
The interval between the cleaning cycles depends greatly on the operating conditions.
Cleaning should normally take place about every 50 hours of operation.
Principle of dry cleaning

During dry cleaning, the dirt coating is removed by the mechanical action of the impacting
solids (granulate).
Operating state
The dry cleaning of the turbine end components is carried out at an engine load of
5 … 85%.
Cleaning several turbochargers

If several turbochargers are installed on an engine, ABB Turbo Systems recommends clean-
ing one turbine after the other.
6.5.2 Procedure for dry cleaning the turbine
Dry cleaning device

Page 40 / 108
Fig. 19: Overview of dry cleaning device
11 Granulate container (51702) 16 Protection valve [closed] (51713)

12 Cover cap (51703) 17 Pressurised air valve [venting] (51704)
13 Pressurised air supply [4 ... 7 bar] 18 Plate
14 Piping 19 Cleaning instructions (51717)
15 On-Off valve [closed] (51705) 20 Gas inlet casing, insulated
CAUTION
Protecting the pressurised air system
u Protect the pressurised air system against overpressure (> 7 bar).
Operating the dry cleaning device
CAUTION
Escape of burnt granulate particles
Careless handling may result in incompletely burnt particles of granulate
and soot particles escaping from the stack with the exhaust gas.
u Only inject the specified amount of granulate for cleaning.
u Make sure that the conditions with regard to the operating state and the maximum ex-
haust gas temperature before the turbine are observed.
u Check that the protection valve (16) is closed (see Fig. 19: Overview of dry cleaning device
→40).
u Check that the on-off valve (15) is closed.
u Check that the combined pressurised air valve/pressure release valve (17) is in the neutral
position.
u Loosen and carefully remove the cover cap (12).
u Fill the specified amount of granulate into the container (11).
u Screw on and tighten the cover cap (12).
Page 41 / 108
u Open the combined pressurised air valve/pressure release valve (17) (down lever posi-
tion).
u Open the protection valve (16).
u Open the on-off valve (15) for cleaning the turbine for 3 ... 4 minutes.
u Close the on-off valve (15).
u Close the protection valve (16).
u Set the combined pressurised air valve/pressure release valve (17) to venting (up lever po-
sition).
u Check that the exhaust gas temperature after the turbine is less than before the cleaning.
u Move the combined pressurised air valve/pressure release valve (17) to the neutral posi-
tion.
Repeating the cleaning

If the cleaning is still unsuccessful after three processes, it is recommended to have the tur-
bocharger checked and cleaned by an ABB Turbocharging Service Station if the engine val-
ues are unsatisfactory.
Optimum cleaning effect

It is important that the specified amount of granulate is blown in for each cleaning process
in order to achieve an optimum cleaning effect.
6.5.3 Cleaning parameters for dry cleaning
Material selection
Possible suppliers of material for dry cleaning can be found on the Internet.
The following materials are suitable for dry cleaning:
¡ Hard, granulated materials (such as natural core granulates)
¡ Soft-blast media
¡ Activated carbon particles
The average grain size of the cleaning granulate must be between 1.2 and 2.0 mm.
The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.
Amount of granulate per turbocharger

Product Quantity [dm3]
A265-L 1.0
A270-L 1.5
A275-L 2.0
Page 42 / 108
A280-L 2.5
Table 14: Cleaning parameters
NOTICE
Storage of dry cleaning materials
The cleaning material must be stored in a dry and clean location to prevent
blockage of the pipes when cleaning.
6 Periodic maintenance / 6.6 Draining the gas outlet casing
6.6 Draining the gas outlet casing

If there is a boiler leak into the exhaust gas pipe or an ingress of water due to other causes,
the gas outlet casing can be drained.
Fig. 20: Drain pipe diagram
01 Drain pipe A Position 1
Page 43 / 108
02 Drain cock B Position 2
03 Drain
04 Air line from compressor casing
u On the drain pipe (01), set the drain cock (02) to position 1 (A).
If the drain pipe (01) is blocked:

u Set the drain cock (02) to position 2 (B) and clean the drain pipe (01) with air from the
compressor casing (04).
If cleaning with air is not sufficient, the drain pipe (01) must be cleaned mechanically.
7 Troubleshooting / 7.1 Malfunctions when starting
7 Troubleshooting
7.1 Malfunctions when starting
Delayed start-up
Possible causes Remedy
Turbocharger Turbocharger contaminated Clean (Periodic maintenance →30)
Bearing damaged Contact ABB Turbocharging Service Sta-
Rotor rubbing tion
Foreign object in the turbocharger
Table 15: Malfunctions when starting – Delayed start-up
Vibrations
Turbocharger Rotor unbalance Contact ABB Turbocharging Service Sta-
Turbine or compressor damaged tion
Bearing damaged
Page 44 / 108
Engine Vibrations from engine Contact enginebuilder

Table 16: Malfunctions when starting – Vibrations
Rubbing of rotating parts

Normal behaviour, not a malfunction
Turbocharger A slight amount of uniform wear at the circumference of the rotor components
caused by slight local rubbing against adjacent components is permitted. This
causes the compressor or turbine blades to be somewhat shortened. To prevent
significant loss of efficiency, specific tolerances must be fulfilled.
¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur-
¡ Have a dimension check carried out by an ABB Turbocharging Service Sta-
tion.
Table 17: Malfunctions when starting – Rubbing of rotating parts
7 Troubleshooting / 7.2 Malfunctions during operation
7.2 Malfunctions during operation
Lubricating oil pressure too low
WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
u Cordon off danger area.
u Raise the alarm and, depending on the situation, stop the engine.
u Seal the oil leak.
u Soak up oil and dispose of in an environmentally compatible manner.

Turbocharger Axial clearance of the rotor excessive Contact an ABB Turbocharging
Service Station
Page 45 / 108
Engine Oil filter heavily contaminated Clean
Oil pump in lubricating system defective Check/replace
Manometer displays incorrectly Replace manometer
Table 18: Malfunctions during operation – Lubricating oil pressure too low
Drop in speed
Turbocharger Heavy contamination of the turbine Clean
Damaged rotor components or bearing Contact ABB Turbocharging Service Sta-
tion
Pipes Defects, such as leaks, in the exhaust gas Repair
pipes or charge air ducts
Table 19: Malfunctions during operation – Drop in speed
7 Troubleshooting / 7.2 Malfunctions during operation
Exhaust gas temperature too high

Engine performance and engine speed unchanged

Turbocharger Insufficient air, for example, when fil- Clean (Periodic maintenance →30)
ter silencer is blocked by dirt
Compressor/turbine contaminated
Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si-
lencer
Turbine damaged or eroded Contact ABB Turbocharging Service Sta-
tion
Engine Malfunction in the injection system Repair or contact manufacturer
Charge air Cooler contaminated Clean
cooler Cooling water volume too low Fill
Inlet temperature of cooling water too Check/clean cooling system
high
Insufficient ventilation Improve ventilation
Table 20: Malfunctions during operation – Exhaust gas temperature too high
Charge air pressure too low

Page 46 / 108
Engine performance and engine speed unchanged, suction condition normal

Turbocharger Manometer display not correct Replace manometer
Supply pipe to manometer not sealed Repair leak
Filter silencer contaminated, therefore Clean (Periodic maintenance →30)
pressure drop too high
Compressor end and/or turbine end con-
taminated
Compressor/turbine damaged Contact ABB Turbocharging Service Sta-
tion
Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si-
lencer
Engine Air receiver not sealed Repair
Gas pipe between engine and turbine not
sealed
Injection mistimed Set correctly
Valve control misadjusted
Pipes Pipes downstream to the compressor Repair.
outlet not sealed.
Table 21: Malfunctions during operation – Charge air pressure too low
7 Troubleshooting / 7.3 Surging of the turbocharger
Charge air pressure too high

Engine performance and engine speed unchanged, suction condition normal

Turbocharger Manometer display not correct Replace manometer
Engine Malfunction in the injection system Repair or contact manufacturer
Injection mistimed Set correctly
Engine performance higher than indic- Check engine performance
ated
Table 22: Malfunctions during operation – Charge air pressure too high
7.3 Surging of the turbocharger
Surging of the turbocharger

Turbocharger Filter silencer or diffuser contamin- Clean (Periodic maintenance →30)
ated
Heavy dirt deposits in the turbine or in
the nozzle ring
Page 47 / 108
Engine Protective grating in front of the tur- Clean/replace
bocharger contaminated or damaged
Charge air Cooler contaminated Clean
cooler Charge air duct blocked
Table 23: Surging of the turbocharger
CAUTION
Continuous or periodic surging
If the turbocharger surges continuously or periodically, parts of the tur-
bocharger may be damaged.
u Gradually reduce the engine load.
u Have the cause clarified and remedied immediately by an ABB Turbochar-
ging Service Station.
u Have parts assessed for damage and, if necessary, replaced by an ABB
Turbocharging Service Station.
7 Troubleshooting / 7.4 Malfunctions when stopping
Sporadic surge blows

Surging of the turbocharger can occur during certain operating states, such as when redu-
cing the engine load quickly when manoeuvring. When this happens, the flow direction in the
compressor is momentarily reversed. Such sporadic surge blows do not impair the safe op-
eration of the turbocharger.
¡ A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer.
7.4 Malfunctions when stopping
Runout noises
Turbocharger Turbocharger contaminated Clean
Bearing damaged Contact an ABB Turbocharging
Rotor rubbing Service Station
Table 24: Malfunctions when stopping – Runout noises
Page 48 / 108
Shortened runout time

Turbocharger Turbocharger contaminated Clean
Bearing damaged Contact an ABB Turbocharging
Rotor rubbing Service Station
Table 25: Malfunctions when stopping – Shortened runout time
7 Troubleshooting / 7.5 Speed measurement system
7.5 Speed measurement system

No signal or Assembly fault The screw plug for the sensor is fitted with a gasket.
poor signal This gasket must be removed when the speed sensor is as-
amplitude sembled. If the gasket has been inadvertently fitted, the distance
present of the sensor tip to the sealing disc giving the signal is increased.
This reduces the voltage amplitude of the speed signal which can
lead to problems with the evaluation electronics.
This problem will be remedied by removing the gasket.
Sensor defective Contact ABB Turbocharging Service Station
Measured Contamination of As the sensor tip is magnetic, it can attract material particles.
speed too the sensor tip This reduces the distance to the auxiliary bearing, which can lead
high to amplification of the noise component and therefore to false
triggering.
Dismantle the sensor, clean the sensor tip, and fit the sensor
back on with the specified tightening torque.
Measured -- Contact ABB Turbocharging Service Station
speed too
low
Other -- If none of the measures described above remedy the malfunc-
causes of tion, it is recommended to have the speed measurement system
malfunction checked by an ABB Turbocharging Service Station.
Table 26: Malfunctions of the speed measurement system
Page 49 / 108
8 Disassembly and assembly / 8.1 Introduction
8 Disassembly and assembly
8.1 Introduction
CAUTION
Further operations
This Operation Manual may be used to carry out only those operations that
are described in it. Further operations that are executed in an incorrect way
can lead to serious damage to the machine.
u ABB Turbo Systems recommends having further operations carried out
only by trained personnel from an ABB Turbocharging Service Station.
u Mark the casing position for assembly.
Identification of the assembly devices

Not all assembly devices are marked with a part number. Identification is guaranteed by the
tool list. This list is enclosed with the toolbox.
Page 50 / 108
WARNING
Servicing the assembly devices
Assembly devices must be checked for damage before and after use.
u Visually inspect for corrosion, cracks, deformation and wear.
u Damaged assembly devices must no longer be used and must be re-
placed.
Customer spare part set

Before starting operations, make sure the required customer spare part set is available (see
chapter Spare parts →100).
Tightening torques for components of the turbocharger

The specified tightening torques of the screw fittings must be observed (Table of tightening
torques →88).
8 Disassembly and assembly / 8.1 Introduction
Tightening torques for assembly devices

Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB
must be tightened so they rest firmly against the surface.
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
u Only fasten the turbocharger, assemblies or individual parts on properly
functional lifting gear with sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.
Wear safety helmet.
Page 51 / 108
Definition of terms
¡ Suspension point
Defined loading point on a component or an assembly (blind hole thread, eyelet, lug).
¡ Assembly device
Devices that are fitted on the turbocharger in order to obtain a suspension point. As-
sembly devices are specially constructed and designed for the defined use; they are not
commercially available products. Use assembly devices only for the described applica-
tions.
¡ Lifting gear
Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting
gear is not supplied by ABB.
8 Disassembly and assembly / 8.2 Weights of assemblies
8.2 Weights of assemblies

The specified weights of the individual parts or assemblies are rounded-up standard values.
Page 52 / 108
Fig. 21: Overview of assembly weights
Position Assembly A265-L A270-L A275-L A280-L

01 Filter silencer 350 470 850 1150
02 Wall insert 300 450 760 1070
03 Diffuser 40 60 110 160
04 Compressor casing 400 620 1030 1350
05 Cover ring 30 50 75 90
06 Nozzle ring 10 20 25 50
07 Gas inlet casing 180 240 380 520
Table 27: Weights of assemblies [kg]
The total weight of the complete wall insert is made up of the wall insert and diffuser as-
semblies.
A265-L A270-L A275-L A280-L

330 510 870 1230
Table 28: Weight of wall insert [kg]
8 Disassembly and assembly / 8.3 Disassembly and assembly of the
filter silencer casing
8.3 Disassembly and assembly of the filter silencer

casing
NOTICE
Disassembly / Assembly of the filter silencer casing
This chapter applies only to turbochargers with filter silencer casing.
Only the assembly of the filter silencer casing is described in detail.
The disassembly must be carried out in reverse order of the assembly.
Page 53 / 108
Fig. 22: Overview of filter silencer casing disassembly and assembly
01, 02 Bottom part

03, 04, 07, 08 Side part
05, 06, 09 Circumferential part
10, 11 Flange
The complete filter silencer casing has the part number 81500.
Assembly
NOTICE
Screws on the filter silencer casing
No screws are tightened until end of filter silencer casing assembly. Only
this way is it possible to fit all the parts.
u Do not tighten the screws during assembly.
Page 54 / 108
Fig. 23: Fitting filter silencer casing 1
u Fit the bottom part (01) to the filter silencer (81000) with screws (A) and (B).
NOTICE
Screw (A)
The location of screw (A) serves as a reference for the correct assembly of
the filter silencer casing.
u Before disassembling the bottom part (01), mark the location of
screw (A).
u Fit all remaining screws on the bottom part (01).
u Fit the bottom part (02) with the screws on the filter silencer.
Page 55 / 108
u Fit the side parts (03) and (04) with the screws on the filter silencer and on the bottom
part.
u Fit the side parts (07) and (08) with the screws on the filter silencer, on the bottom part,
and on the side parts (03, 04).

Page 56 / 108
u Insert the flanges (10) and (11) laterally between the side parts and fit the screws.
u Fit the circumferential part (05) with the screws.
Screws for fastening the individual parts to Screws for fastening the individual parts
the filter silencer
M10 M8
30 Nm 25 Nm
Table 29: Tightening torques (filter silencer screws)
u Tighten all screws of the bottom parts (01) and (02).
u Tighten all screws of the side parts (03, 04, 07, 08) and the flanges (10, 11).
u Tighten all screws of the circumferential parts (05, 06, 09).
Bellows
Page 57 / 108
Fig. 28: Fitting the bellows
u Fit bellows (C) with frame (F), screws (S) and nuts (N) on the filter silencer casing.
8 Disassembly and assembly / 8.4 Dismantling the filter silencer
8.4 Dismantling the filter silencer
8.4.1 Design variants

The turbocharger is equipped with one of the following filter silencer variants:
¡ Welded filter silencer
¡ Cast filter silencer
The filter silencers differ in terms of the fixing eyelets for the lifting gear. The relevant vari-
ant must be taken into consideration for disassembly and assembly.
8.4.2 Dismantling the filter silencer (welded)

u Dismantle the insulation if necessary.
Page 58 / 108
Fig. 29: Dismantling the filter silencer
1. Attach lifting gear to the eyelets of the filter silencer (81000).

2. Loosen nuts (72004) and remove with washers (72003).
3. Remove and put down filter silencer.
8 Disassembly and assembly / 8.4 Dismantling the filter silencer
8.4.3 Dismantling the filter silencer (cast)

u Dismantle the insulation if necessary.
Page 59 / 108
Fig. 30: Dismantling the filter silencer
1. Attach the lifting gear to the front lug and rear eyelet of the filter silencer (81000).
2. Loosen nuts (72004) and remove with washers (72003).
3. Remove and put down filter silencer.
8 Disassembly and assembly / 8.5 Dismantling wall insert and diffuser
8.5 Dismantling wall insert and diffuser
Dismantling the wall insert

Page 60 / 108
Fig. 31: Pressing off compressor casing
1. Loosen one screw (72011) and leave 2/3 of the thread length screwed into the com-
pressor casing (72000).
2. Loosen and remove the remaining screws (72011).
3. Use the press-off screws (90900) to press off the wall insert (77000) from the com-
pressor casing (72000) until the lifting device (90190) can be fitted.
4. Fit shackle (90195) with lifting gear on P1 of lifting device (90190).
5. Fit lifting device (90190) with crane on upper area of wall insert (77000).
6. Change the position of the shackle with the lifting gear to P2 of the lifting device (90190).
Fig. 32: Moving out wall insert
7. Remove screw (72011).
8. Carefully move out the wall insert (77000) with diffuser (79000).
Page 61 / 108
9. Remove the O-ring (77040).
Fig. 33: Putting down wall insert
u Put down wall insert (77000) with diffuser (79000) in horizontal position and use appro-
priate supports to prevent it from falling over and rolling away.
Dismantling the diffuser
WARNING
Support for the wall insert
The support may slip away when the wall insert is placed on flange F.
Any defective or improperly used supports can lead to serious injury to per-
sonnel and even to fatal accidents.
u Check the position of the support and correct if necessary.
WARNING
Risk of tipping
If the wall insert is not tilted, it must be put down correctly. Tipping of the
wall insert may lead to serious injuries to persons or even to fatal accidents.
u If the wall insert is not tilted, ensure that it is fixed correctly (see Dis-
mantling wall insert).
Page 62 / 108
Fig. 34: Putting down wall insert
1. Put wall insert (77000) down on suitable supports.

2. Tilt wall insert (77000) with diffuser (79000) against lifting device (90190).
3. Place wall insert with the flange (F) on the underlay.
Page 63 / 108
Fig. 35: Dismantling the diffuser
4. Loosen and remove screws (77015).

5. Remove O-rings (79020, 79021).
6. Attach lifting gear (L) to the diffuser (79000).
7. Remove and put down diffuser.
8 Disassembly and assembly / 8.6 Axial clearance A prior to disas-
sembly
8.6 Axial clearance A prior to disassembly
WARNING
Physical hazards due to sharp edges on compressor wheel
The compressor wheel has sharp edges which can result in injury.
u Wear safety gloves.

Page 64 / 108
Fig. 36: Measuring axial clearance A
The axial clearance (A) of the rotor should always be measured before and after service work
on the turbocharger.
u Measure and note axial clearance (A).
Product Axial clearance A

[mm]
A265-L 0.32 ... 0.62
A270-L 0.33 ... 0.63
A275-L 0.38 ... 0.68
A280-L 0.41 ... 0.73
Table 30: Admissible axial clearance A
CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an ABB Tur-
8 Disassembly and assembly / 8.7 Dismantling the insulation, the gas
inlet casing and the nozzle ring (A275-L and smaller)
8.7 Dismantling the insulation, the gas inlet casing

and the nozzle ring (A275-L and smaller)
Dismantling the insulation
NOTICE
Dry cleaning
The dry cleaning does not have to be removed to dismantle the insulation.
Page 65 / 108
Fig. 37: Removing the insulation (A275-L and smaller).
1. Loosen and remove screws of insulation jackets (51200) from gas outlet casing (61001).
2. Loosen and remove all connecting plates of insulation jackets.
3. Remove insulation jackets.
4. Detach flange connection between gas inlet casing (51001) and bellows.
Dismantling the gas inlet casing (A275-L and smaller) – screwed variant
Fig. 38: Dismantling the gas inlet casing (A275-L and smaller) – screwed variant
u If one of the screws (61009) shears off when loosening, an ABB Turbocharging Service
Station should be contacted.
Page 66 / 108
1. Loosen crosswise and remove all but two opposite screws (61009).

2. Fit two guide studs (90317) in the upper area on the gas outlet casing.
3. Loop around the gas inlet casing (51001) with lifting gear.
4. Loosen and remove remaining screws (61009).
5. Carefully move out gas inlet casing and put down, remove guide studs.
Dismantling the gas inlet casing (A275-L and smaller) – threaded stud variant
Fig. 39: Dismantling the gas inlet casing (275-L and smaller) – threaded stud variant
Part number A265-L A270-L A275-L

51087 245 Nm 350 Nm 665 Nm
Page 67 / 108
Table 31: Maximum admissible loosening torque (51087)
u If a threaded stud (51086) shears off when loosening, an ABB Turbo Systems Service Sta-
tion should be contacted.
u If a threaded stud (51086) works loose when removing the nut (51087), it should be refit-
ted, after disassembling the gas outlet casing, up to the stop in the gas inlet casing until
hand-tight.
u If the nut (51087) cannot be removed with the maximum permissible loosening torque, it
can be heated and removed with an appropriate tool.
1. Treat nuts (51087) with rust remover.
2. Loosen crosswise and remove all but two opposite nuts (51087). Note maximum admiss-
ible loosening torque.
4. Loosen and remove remaining nuts (51087). Note maximum admissible loosening torque.
5. Carefully move out gas inlet casing and put down.
Dismantling the nozzle ring
Fig. 40: Dismantling the nozzle ring (A275-L and smaller)
1. Loosen screws (56014) and remove with washers (56011).

2. Remove and put down nozzle ring (56001).
Page 68 / 108
8 Disassembly and assembly / 8.8 Dismantling the gas inlet casing,
nozzle ring (A280-L)
8.8 Dismantling the gas inlet casing, nozzle ring

(A280-L)
Dismantling the gas inlet casing (A280-L) – screwed variant
Page 69 / 108
Fig. 41: Dismantling the gas inlet casing (A280-L) – screwed variant
u If one of the screws (61009) shears off when loosening, an ABB Turbocharging Service
Station should be contacted.
1. Dismantle both halves of the insulation segment (51215) and remove with all fixing ele-
ments.
3. Loosen and remove all but two opposite screws (61009).
4. Fit two guide studs (90317) in the upper area on the gas outlet casing (61001).
5. Loop lifting gear around gas inlet casing.
6. Loosen remaining screws and carefully move out gas inlet casing.
7. Fit supports (90481,90482) on gas inlet casing and put down casing.
8. Remove the guide studs.
Dismantling the gas inlet casing (A280-L) – threaded stud variant

Page 70 / 108
Fig. 42: Dismantling the gas inlet casing (A280-L) - threaded stud variant
Part number A280-L

51087 840 Nm
Table 32: Maximum admissible loosening torque (51087)
u If a threaded stud (51086) shears off when loosening, an ABB Turbo Systems Service Sta-
tion should be contacted.
u If a threaded stud (51086) works loose when removing the nut (51087), it should be refit-
ted, after disassembling the gas outlet casing, up to the stop in the gas inlet casing until
hand-tight.
u If the nut (51087) cannot be removed with the maximum permissible loosening torque, it
can be heated and removed with an appropriate tool.
1. Dismantle both halves of the insulation segment (51215) and remove with all fixing ele-
ments.
3. Treat nuts (51087) with rust remover.
4. Loosen crosswise and remove all but two opposite nuts (51087). Note maximum loosen-
ing torque.
6. Loosen and remove remaining nuts (51087). Note maximum admissible loosening torque.
7. Fit supports (90481, 90482) on gas inlet casing and put down casing.
Dismantling the nozzle ring
Fig. 43: Fitting the nozzle ring holder (A280-L)
Page 71 / 108
1. Remove screws (B2).
2. Fit the nozzle ring holder (90477) with screws (B1) at the top of the flange of the gas inlet
casing (51001).
Page 72 / 108
Fig. 44: Dismantling the nozzle ring (A280-L)
1. Loop around the nozzle ring holder (90477) with the lifting gear and secure it to the
crane.
2. Loosen screws (56014) and remove with washers (56011).
3. Pull the nozzle ring (56001) towards the front onto the nozzle ring holder (90477).
4. Screw the screws (B2) into the nozzle ring holder.
Fig. 45: Putting down the nozzle ring (A280-L)
u Use the crane to remove and put down the nozzle ring (56001).
8 Disassembly and assembly / 8.9 Fitting gas inlet casing, nozzle ring,
insulation (A275-L and smaller)
8.9 Fitting gas inlet casing, nozzle ring, insulation

(A275-L and smaller)
Fitting the nozzle ring

u Coat the screw threads with high-temperature grease.
Page 73 / 108
Fig. 46: Fitting the nozzle ring (A275-L and smaller)

56014 M10 M10 M10
35 Nm 35 Nm 35 Nm
Table 33: Tightening torque (56014)
1. Align the notch (A1) with the flange connection (A2) and slide the nozzle ring (56001) into
the gas inlet casing (51001).
2. Fit screws (56014) with high-temperature grease and washers (56011).
Fitting the gas inlet casing (A275-L and smaller) - screwed variant
Page 74 / 108
Fig. 47: Fitting the gas inlet casing (A275-L and smaller) - screwed variant

61009 M16 M18 M22
301) Nm 401) Nm 501) Nm
140 Nm 200 Nm 380 Nm
1) Pre-tightening torque of the screws

2. Loop around the gas inlet casing (51001) with the lifting gear and secure it to the crane.
3. Push gas inlet casing over the guide studs up to the gas outlet casing.
4. Screw in two opposite screws (61009) with high-temperature grease.
5. Remove the guide studs (90317) and fit the remaining screws (61009) with high-temper-
ature grease.
6. Fit the screws (61009) by tightening them crosswise, first to the pre-tightening torque,
then to the tightening torque.
7. Remove the lifting gear.
8. Connect the flange of the gas inlet casing and the bellows.
Fitting the gas inlet casing (A275-L and smaller) - threaded stud variant
Page 75 / 108
Fig. 48: Fitting the gas inlet casing (A275-L and smaller) - threaded stud variant

51087 M16 M18 M22
301) Nm 401) Nm 501) Nm
140 Nm 200 Nm 380 Nm
1) Pre-tightening torque of the nuts

1. Coat threaded stud (51086) with high-temperature grease, screw in up to the stop in the
gas outlet casing (61001) and tighten hand-tight.
3. Push gas inlet casing over the threaded studs up to the gas outlet casing.
4. Coat two nuts with high-temperature grease and fix gas inlet casing in two opposite po-
sitions.
5. Coat remaining nuts with high-temperature grease, fit and then tighten crosswise, ini-
tially to the pre-tightening torque and then to the tightening torque.
Fitting insulation
Fig. 49: Fitting the insulation (A275-L and smaller)

Page 76 / 108
1. Fit flange connection between gas inlet casing (51001) and bellows.

2. Fit the insulation jackets (51200) on the gas inlet casing (51001) with the screws.
3. Fit connecting plates of insulation jackets with screws.
4. Fit insulation jackets with screws on gas outlet casing (61001).
8 Disassembly and assembly / 8.10 Fitting the gas inlet casing, nozzle
ring (A280-L)
8.10 Fitting the gas inlet casing, nozzle ring (A280-L)
Fitting the nozzle ring

u Coat the screw threads with high-temperature grease.
Page 77 / 108
Fig. 50: Fitting the nozzle ring (A280-L)
u Use lifting gear to secure the nozzle ring (56001) on the nozzle ring holder (90477) and
transport it.
ring (A280-L)
Page 78 / 108
Fig. 51: Attaching the nozzle ring (A280-L)
Part number A280-L

56014 M12
65 Nm
1. Fit the nozzle ring holder (90477) on the flange of the gas inlet casing (51001) with
screws (B1).
3. Align the notch (A1) on the cam of the nozzle ring (56001) with the flange connection (A2)
and slide the nozzle ring into the gas inlet casing.
4. Coat screws (56014) with high-temperature grease and fit with washers (56011).
5. Remove screws (B1) along with the nozzle ring holder (90477).
ring (A280-L)
Fitting the gas inlet casing (A280-L) – screwed variant
Page 79 / 108
Fig. 52: Fitting the gas inlet casing (A280-L) – screwed variant
Part number A280-L

61009 M24
801) Nm
480 Nm

3. Dismantle and remove supports (90481, 90482) from the gas inlet casing.
4. Push gas inlet casing over the guide studs up to the gas outlet casing.
5. Coat two opposite screws (61009) with high-temperature grease and screw in.
6. Remove the guide studs.
7. Coat remaining screws with high-temperature grease and fit. Fit the screws by tighten-
ing them crosswise, first to the pre-tightening torque, then to the tightening torque.
9. Connect the flanges of the gas inlet casing and the bellows.
10. Fit the insulation segments (51215).
ring (A280-L)
Fitting the gas inlet casing (A280-L) – threaded stud variant

Page 80 / 108
Fig. 53: Fitting the gas inlet casing (A280-L) – screwed variant
Part number A280-L

51087 M24
801) Nm
480 Nm

1. Coat threaded stud (51086) with high-temperature grease, screw in up to the stop in the
gas outlet casing (61001) and tighten hand-tight.
3. Dismantle and remove supports (90481, 90482) from the gas inlet casing.
4. Push gas inlet casing over the threaded studs up to the gas outlet casing.
5. Coat two nuts with high-temperature grease and fix gas outlet casing in two opposite
positions.
6. Coat remaining nuts with high-temperature grease, fit and then tighten crosswise, ini-
tially to the pre-tightening torque and then to the tightening torque.
9. Fit the insulation segments (51215).
8 Disassembly and assembly / 8.11 Axial clearance A after assembly
8.11 Axial clearance A after assembly
WARNING
Physical hazards due to sharp edges on compressor wheel
The compressor wheel has sharp edges which can result in injury.
u Wear safety gloves.
Page 81 / 108
Fig. 54: Measuring axial clearance A
The axial clearance (A) of the rotor should always be measured before and after service work
on the turbocharger.
u Measure and note axial clearance (A).
Product Axial clearance A

[mm]
A265-L 0.32 ... 0.62
A270-L 0.33 ... 0.63
A275-L 0.38 ... 0.68
A280-L 0.41 ... 0.73
Table 39: Admissible axial clearance A
CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an ABB Tur-
8 Disassembly and assembly / 8.12 Fitting diffuser, wall insert
8.12 Fitting diffuser, wall insert
Fitting the diffuser

Page 82 / 108
Fig. 55: Fitting the diffuser

77015 M5 M6 M8 M8
6 Nm 10 Nm 25 Nm 25 Nm
1. Attach lifting gear (L) to the diffuser (79000).

2. Carefully place the diffuser on the wall insert (77000), then remove lifting gear.
3. Fit new O-rings (79020, 79021) on the diffuser.
4. Degrease screws (77015) and threaded holes in wall insert.
5. Coat threads of the screws with Loctite® 542.
6. Fit screws.
Fitting the wall insert
Fig. 56: Positioning wall insert
u Carefully bring wall insert (77000) into vertical position with the lifting device (90190).
Page 83 / 108
Page 84 / 108
Fig. 57: Fitting the wall insert

72011 M18 M20 M24 M27
370 Nm 500 Nm 900 Nm 1300 Nm
1. Attach the new O-ring (77040) to the wall insert (77000).

2. Fit two guide studs (90320) in the upper area of the compressor casing (72000).
3. Align arrow markings of wall insert (77000) and compressor casing to one another.
4. Carefully move the wall insert with diffuser (79000) over the guide studs into the com-
pressor casing.
5. Fit a screw (72011) as a safeguard.
6. Change the position of the shackle (90195) with the lifting gear to P1 of the lifting device
(90190) and remove with the crane.
7. Completely insert the wall insert and then remove the guide studs (90320).
Check that both casings are in the correct position (the marking arrows are aligned to
one another).
8. Fit screws (72011).
8 Disassembly and assembly / 8.13 Fitting the filter silencer
8.13 Fitting the filter silencer
8.13.1 Design variants

The turbocharger is equipped with one of the following filter silencer variants:
¡ Welded filter silencer
¡ Cast filter silencer
The filter silencers differ in terms of the fixing eyelets for the lifting gear. The relevant vari-
ant must be taken into consideration for disassembly and assembly.
8.13.2 Fitting the filter silencer (welded)
Page 85 / 108
Fig. 58: Fitting the filter silencer

72004 M14 M16 M18 M20
130 Nm 200 Nm 300 Nm 420 Nm
2. Position filter silencer on compressor casing.
3. Fit nuts (72004) with washers (72003) and tighten.
u Fit insulation as far as necessary.
8.13.3 Fitting the filter silencer (cast)

Page 86 / 108
Fig. 59: Fitting the filter silencer

72004 M14 M16 M18 M20
130 Nm 200 Nm 300 Nm 420 Nm
2. Position filter silencer on compressor casing.
3. Fit nuts (72004) with washers (72003) and tighten.
u Fit insulation as far as necessary.
Page 87 / 108
8 Disassembly and assembly / 8.14 Table of tightening torques
8.14 Table of tightening torques

Page 88 / 108
Fig. 60: Overview of tightening torques
Fig. 61: Overview of speed sensor tightening torque
8 Disassembly and assembly / 8.14 Table of tightening torques
Position Part number A265-L A270-L A275-L A280-L

22 57005 M12 M12 M16 M20
50 50 80 160
61 1) 61009 M16 M18 M22 M24
51087 302) 40 2) 50 2) 80 2)
140 200 380 480
62 1) 72011 M18 M20 M24 M27
370 500 900 1300
63 1) 72004 M14 M16 M18 M20
130 200 300 420
63a 72002 M14 M16 M18 M20
40 60 80 100
64 77015 M5 M6 M8 M8
6 10 25 25
65 56014 M10 M10 M10 M12
35 35 35 65
66 81125 G1/2" G1/2" G1/2" G1/2"
45 45 45 45
67 86505 M18x1.5 M18x1.5 M18x1.5 M27x2
150 150 150 320
Table 44: Overview of tightening torques
1) Tighten crosswise
Page 89 / 108
u Use hydraulic tool for tightening torques exceeding 500 Nm.
Thread size Tightening torque [Nm]

M8 28
M10 45
M12 (compressor casing insulation) 50
Table 45: Tightening torque, insulation
9 Taking a turbocharger out of operation / 9.1 Possible emergency re-
pairs
9 Taking a turbocharger out of operation
9.1 Possible emergency repairs
WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
u Cordon off danger area.
u Raise the alarm and, depending on the situation, stop the engine.
u Seal the oil leak.
u Soak up oil and dispose of in an environmentally compatible manner.
CAUTION
Page 90 / 108
Machine damage in emergency operation

The assembly of the locking device on the turbocharger is only permissible
in emergencies. It is not permitted to lock the rotor for an engine test. Seri-
ous damage to engine or property can be caused by non-compliance with
the regulations in the event of an emergency.
u The permissible turbocharger speed for the unlocked turbocharger may
not exceed 45% of nBmax. Take note of the rating plate.
u After locking the turbocharger, contact an ABB Turbocharging Service
Station and find the nearest port.
u Observe the safety regulations.
u Follow the directives of the enginebuilder.
CAUTION
Machine damage following emergency operation
Impermissible vibrations and unbalance values can cause serious damage to
the engine or property during operation. It is imperative that the following
work is carried out after emergency operation with a locked rotor by an ABB
Turbocharging Service Station:
u Remove rotor and check for unbalance
u Install rotor
u Fitting the spinner nose cone
9 Taking a turbocharger out of operation / 9.2 Taking defective tur-
bochargers out of operation
CAUTION
Machine damage due to overheating
Serious damage to engine or property can be caused by the overheating of
intact turbocharger components.
u If there is a lubricating oil leak on the turbocharger, stop the oil supply.
9.2 Taking defective turbochargers out of operation

In the event of turbocharger damage, the turbocharger must be taken out of operation. In
order to ensure that the engine can continue operation as quickly as possible, observe the
following instructions.
9.2.1 Procedure with one turbocharger installed per engine

u Stop the engine.
u Close off oil supply to defective turbocharger.
u Dismantle filter silencer (see chapter Dismantling the filter silencer →58).
Page 91 / 108
u Lock rotor with locking device (see chapter Locking the rotor →92)
Version Procedure
With bypass Open bypass
(see chapter Engines with bypass around the turbocharger →93)
Without bypass If necessary, remove the nozzle ring
(see chapter Engines without bypass around the turbocharger
→94)
Table 46: Bypass procedure
u Continue to operate engine in accordance with enginebuilder's instructions. Observe the

prescribed power reduction.
9.2.2 Procedure with two or more installed turbochargers per

engine
CAUTION
Machine damage due to too high a speed
The permissible turbocharger speed for the unlocked turbocharger may not
exceed 45% of nBmax. Serious damage to engine or property can be caused by
excessive speeds.
u Observe the permissible turbocharger speed for the unlocked turbochar-
ger.
u Reduce the engine load if necessary.
u Stop the engine.
u Close off oil supply to defective turbocharger.
u Blank off the inlets and outlets of the defective turbocharger (see chapter Blanking off
the inlets and outlets →94).
u Continue to operate engine in accordance with enginebuilder's instructions. Observe the
prescribed power reduction.
Page 92 / 108
9.2.3 Locking the rotor
Fig. 62: Locking the rotor
Product B1 [Nm] B2 [Nm] B3 [Nm]

A265-L M8 M12 M8
25 75 25
A270-L M10 M12 M8
45 75 25
A275-L M10 M12 M8
45 75 25
A280-L M12 M12 M8
75 75 25
Table 47: Tightening torque B1, B2, B3
u Dismantle the filter silencer

(Dismantling the filter silencer →58).
1. If present: Unscrew and remove the connecting screw at the centre of the spinner nose
cone (25012). Dismantle spinner nose cone with press-off screw (90924).
2. Loosen retaining nuts (N) and remove screws (B1).
3. Loosen screws (B2) and remove with washers.
4. Align the locking device to a fin of the wall insert (77000) and align the hole circle to the
drill holes in the compressor wheel (25000).
5. Secure the locking device to the compressor wheel with the maximum possible number
Page 93 / 108
of screws (B1). Observe the tightening torque. Assembly with at least 6 screws is mandat-
ory. The maximum possible number of screws to be fitted (B1) varies, as the threads in
the compressor wheel are partially occupied by set screws.
6. Align the bracket (94020) to a fin of the wall insert and fit screws (B2) with washers and
screw (B3). Observe the tightening torque.
9.2.4 Engines with bypass around the turbocharger

The chapter only applies for engines with one turbocharger and for systems on which the
connections for a bypass have been prepared and the necessary pipe connections have been
provided.
u Close the lubricating oil supply to the turbocharger.
u Open the bypass around the turbocharger.
u Observe specifications from enginebuilder.
9.2.5 Engines without bypass around the turbocharger

To obtain a higher engine performance, the nozzle ring can be removed if required (see
chapter Disassembly and assembly →50).
Securing the cover ring

If the nozzle ring is removed for emergency operation, the clamping of the cover ring (57001)
to the gas outlet casing must be ensured. In this case, additional washers (01) must be
provided in accordance with the following table. These washers (01) are not supplied by ABB.
Page 94 / 108
Fig. 63: Ensuring clamping of the cover ring
Product h [mm] d1 [mm] d2 [mm]

A265-L 3.5 … 4.0 13 20
A270-L 3.5 … 4.0 13 20
A275-L 4.0 … 5.0 17 28
A280-L 4.0 … 5.0 21 34
Table 48: Required washers (01)

57005 M12 M12 M16 M20
50 Nm 50 Nm 80 Nm 160 Nm
1. Remove screws (57005).
2. Fit and tighten screws (57005) with high-temperature grease and washers (01) in accord-
ance with the table.
9.2.6 Blanking off the inlets and outlets

The chapter is only applicable for engines with several turbochargers and joint air and ex-
haust gas receivers. The cover plates for the compressor casing outlet, gas inlet and gas
outlet are not included in the ABB scope of delivery.
The following figure shows the positions where to fit the cover plates.
Fig. 64: Position of cover plates
u Stop the engine.
Page 95 / 108
u Shut off the supply of lubricating oil to the turbocharger.
u Blank off flanges of compressor casing outlet (01), gas inlet (02) and gas outlet (03) by in-
stalling cover plates.
u Observe specifications from enginebuilder.
Page 96 / 108
10 Mothballing the turbocharger / 10.1 Taking the engine out of opera-
tion for up to 12 months
10 Mothballing the turbocharger
10.1 Taking the engine out of operation for up to

12 months
State of the engine lubricating oil

The turbocharger normally remains attached to the engine. The measures to be taken for
mothballing the turbocharger depend on the state of the lubricating oil. No measures are re-
quired under the following conditions:
¡ Acid number (TAN) < 2 mg KOH/g
¡ The engine lubricating oil is replaced by a preservative oil and circulated with the pre-lub-
rication pump before the engine is taken out of operation. Residues of old engine oil are
flushed away in this way and the bearing parts are largely protected against corrosion.
Preparations for mothballing
Page 97 / 108
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
Wear a respiratory mask to protect against gases.
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures
are necessary after taking the engine out of operation:
u Dismantle the turbocharger.
u The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur-
u Clean all parts.
10 Mothballing the turbocharger / 10.2 Taking the engine out of oper-
ation for more than 12 months
u Coat plain surfaces of steel and cast parts with anticorrosive oil.
u Fit turbocharger completely.
Rotation of the rotor in the stack draught

If the rotor turns as a result of the stack draught:
u Install a blind flange between the outlet flange of the compressor casing and the charge
air duct.
10.2 Taking the engine out of operation for more than

12 months
If the engine is taken out of operation, the following variants are possible with regard to the
turbocharger:
¡ Turbocharger remains attached to the engine
¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing
parts are dismantled by an ABB Turbocharging Service Station and stored separately
¡ The turbocharger is completely removed, either as a whole unit or in individual parts
Page 98 / 108
For the measures always necessary for preparing the turbocharger parts for mothballing,
see section Taking the engine out of operation for up to 12 months, subsection Preparations
for mothballing.
If the turbocharger remains attached to the engine, see section Taking the engine out of op-
eration for up to 12 months, subsection Rotor turning in stack draught.
If the complete turbocharger is removed or the turbocharger is assembled again from the
individual parts:
u Seal all openings of the turbocharger with paraffin paper and wooden lids.
Only dry rooms with 40 ... 70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.
State of the mothballed turbocharger

u Check the turbocharger parts annually for corrosion.
u If there are signs of rust: Thoroughly clean parts and renew corrosion protection.
11 Disposing of turbocharger components /
11 Disposing of turbocharger components

WARNING
Handling damaged thermal insulation
Damaged thermal insulation can lead to dust exposure. The glass fibres can
cause mechanical irritation of the eyes, skin, and respiratory tracts.
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against dusts (P1 or P2 mask).
u Wear work gloves made of leather.
Wear a respiratory mask to protect against dusts.
Page 99 / 108
Disposal must be environmentally compatible, professional, and in compliance with locally
applicable regulations.
The turbocharger consists largely of metal (cast iron materials, steel, nickel-steel alloys, alu-
minium and bearing brass).
Further components are: Non-metallic materials (filter components of felt and polyethylene),
lubricants (engine oil), electronic parts (speed sensor and associated components), and
thermal insulation.
u Dispose of metals as scrap metal for recycling.
u Dispose of non-metallic materials as waste.
u Dispose of residues of lubricants as waste oil.
u Dispose of electronic components as electronic waste.
u Dispose of thermal insulation as hazardous waste.
12 Spare parts / 12.1 Ordering spare parts
12 Spare parts
12.1 Ordering spare parts
CAUTION
Spare part storage
All spare parts that were ordered together with the turbocharger must be
kept intact and ready for use.
u Carefully clean any rusted parts and grease them.
Please quote the following data when making queries and ordering spare parts:
¡ Turbocharger type
¡ Serial number of the turbocharger
¡ Designation and part number
Spare parts can be ordered from any ABB Turbocharging Service Station.
Page 100 / 108
u If different model variants are not taken into account in this document, contact an ABB
Turbocharging Service Station.
The customer spare part sets (97070 / 97071) are available for the work described in the op-
eration manual. The customer spare part set required depends on the service work being
carried out on the turbocharger. The parts are only available in the complete set.
Customer spare part set (97070)

Customer spare part set is required for service work on the turbocharger after 36,000 hours.
Quantity Designation Part number

3 Washer 56011
3 Hexagon-head screw 56014
3 Washer 72003
3 Hexagon nut 72004
2 Hexagon-head screw 77015
1 O-ring 77040
1 O-ring 79020
1 O-ring 79021
1 O-ring 86506
Table 50: Customer spare part set (97070)
12 Spare parts / 12.1 Ordering spare parts
Customer spare part set (97071)

Customer spare part set is required for service work on the turbocharger after 18,000 hours.
Quantity Designation Part number

1 O-ring 77040
1 O-ring 79020
1 O-ring 79021
Table 51: Customer spare part set (97071)
u Dispose of replaced parts and parts that are not reusable in a professional and environ-
mentally compatible manner.
Page 101 / 108
12 Spare parts / 12.2 View of turbocharger with part numbers
12.2 View of turbocharger with part numbers

Page 102 / 108
Fig. 65: View of turbocharger with part numbers
12 Spare parts / 12.2 View of turbocharger with part numbers
Turbocharger
Part number Designation
-- Cartridge group
51001 Gas inlet casing
56001 Nozzle ring
56011 (in the customer spare part set) Washer
56014 (in the customer spare part set) Hexagon-head screw
51086 Threaded stud
51087 Hexagon nut
57001 Cover ring
57005 Hexagon-head screw
61001 Gas outlet casing
68002 Foot, turbine end
72000 Compressor casing
72002 Threaded stud
72003 (in the customer spare part set) Washer
72004 (in the customer spare part set) Hexagon nut
74040 Air outlet silencer (option)
Page 103 / 108

74042 Gasket (option)
77000 Wall insert
77015 (in the customer spare part set) Hexagon-head screw
77040 (in the customer spare part set) O-ring
79000 Diffuser
81000 Filter silencer
Table 52: Turbocharger with part numbers
12 Spare parts / 12.3 View of cartridge group with part numbers
12.3 View of cartridge group with part numbers

Page 104 / 108
Fig. 66: View of cartridge group with part numbers
NOTICE
Cartridge group
The cartridge group is not delivered as a fitted assembly. Spare parts must
be ordered individually.
12 Spare parts / 12.3 View of cartridge group with part numbers
Cartridge group
Part number Designation
21000 Turbine
25000 Compressor wheel
25008 Threaded stud
25009 Ring nut
25012 Spinner nose cone
25013 Screw
25014 Washer
32001 Thrust bearing
32101 Radial bearing, compressor end
32102 Radial bearing, turbine end
32105 Floating disc
32106 Axial bearing
32109 Sealing disc
32159 Locking screw
32174 O-ring
42001 Bearing casing
42008 Socket screw
42011 O-ring
Page 105 / 108

42015 Sealing cover
42041 Gasket
42185 Socket screw
42186 O-ring
42295 Pressure adjusting unit
42300 Partition wall
42305 O-ring
42306 O-ring
42307 O-ring
42320 Socket screw
42458 Blind flange
86505 Speed sensor
Table 53: Cartridge group with part numbers
Figures
Figures
Fig. 1: Layout and function of the turbocharger ...... 4 Fig. 32: Moving out wall insert .................................... 61
Fig. 2: Warning plate locations .................................... 6 Fig. 33: Putting down wall insert ................................ 61
Fig. 3: Locations of the rating plates .......................... 7 Fig. 34: Putting down wall insert ................................ 62
Fig. 4: Fitting lifting gear to turbocharger................ 9 Fig. 35: Dismantling the diffuser ............................... 63
Fig. 5: Placing the turbocharger on the bracket ..... 10 Fig. 36: Measuring axial clearance A .......................... 64
Fig. 6: Compressor-end foot....................................... 11 Fig. 37: Removing the insulation (A275-L and smal-
ler)..................................................................................... 65
Fig. 7: Turbine-end foot................................................ 11
Fig. 38: Dismantling the gas inlet casing (A275-L and
Fig. 8: Layout and overview of the speed measure- smaller) – screwed variant ........................................... 66
ment system................................................................... 18
Fig. 39: Dismantling the gas inlet casing (275-L and
Fig. 9: Replacing the speed sensor ........................... 20 smaller) – threaded stud variant ................................ 67
Fig. 10: U-tube manometer at the filter silencer..... 21 Fig. 40: Dismantling the nozzle ring (A275-L and
smaller) ............................................................................ 68
Fig. 11: Noise insulation, bellows................................ 23
Fig. 41: Dismantling the gas inlet casing (A280-L) –
Fig. 12: Layout and overview of filter silencer ......... 31 screwed variant.............................................................. 69
Fig. 13: Dismantling filter ring circumferential part ....
Page 106 / 108
Fig. 42: Dismantling the gas inlet casing (A280-L) -

33 threaded stud variant ................................................... 70
Fig. 14: Opening filter ring lock................................... 33 Fig. 43: Fitting the nozzle ring holder (A280-L) ........71
Fig. 15: Attaching new filter ring ............................... 34 Fig. 44: Dismantling the nozzle ring (A280-L).......... 72
Fig. 16: Fitting new filter ring..................................... 34 Fig. 45: Putting down the nozzle ring (A280-L) ....... 72
Fig. 17: Overview of wet cleaning of compressor ... 37 Fig. 46: Fitting the nozzle ring (A275-L and smaller) ...
73
Fig. 18: Filter plug view................................................ 38
Fig. 47: Fitting the gas inlet casing (A275-L and
Fig. 19: Overview of dry cleaning device .................. 40
smaller) - screwed variant............................................ 74
Fig. 20: Drain pipe diagram ........................................ 43
Fig. 48: Fitting the gas inlet casing (A275-L and
Fig. 21: Overview of assembly weights .................... 52 smaller) - threaded stud variant ................................. 75
Fig. 22: Overview of filter silencer casing disas- Fig. 49: Fitting the insulation (A275-L and smaller).....
sembly and assembly .................................................. 53 76
Fig. 23: Fitting filter silencer casing 1....................... 54 Fig. 50: Fitting the nozzle ring (A280-L) ................... 77
Fig. 24: Fitting filter silencer casing 2 ...................... 55 Fig. 51: Attaching the nozzle ring (A280-L) .............. 78
Fig. 25: Fitting filter silencer casing 3 ...................... 55 Fig. 52: Fitting the gas inlet casing (A280-L) –
screwed variant.............................................................. 79
Fig. 26: Fitting filter silencer casing 4 ...................... 56
Fig. 53: Fitting the gas inlet casing (A280-L) –
Fig. 27: Fitting filter silencer casing 5 ...................... 56 screwed variant.............................................................. 80
Fig. 28: Fitting the bellows .......................................... 57 Fig. 54: Measuring axial clearance A .......................... 81
Fig. 29: Dismantling the filter silencer ..................... 58 Fig. 55: Fitting the diffuser.......................................... 82
Fig. 30: Dismantling the filter silencer ..................... 59 Fig. 56: Positioning wall insert.................................... 83
Fig. 31: Pressing off compressor casing.................. 60 Fig. 57: Fitting the wall insert ..................................... 84
Figures
Fig. 58: Fitting the filter silencer ............................... 85
Fig. 59: Fitting the filter silencer ............................... 86
Fig. 60: Overview of tightening torques.................. 88
Fig. 61: Overview of speed sensor tightening torque.

88
Fig. 62: Locking the rotor............................................ 92
Fig. 63: Ensuring clamping of the cover ring .......... 94
Fig. 64: Position of cover plates................................ 95
Fig. 65: View of turbocharger with part numbers 102
Fig. 66: View of cartridge group with part numbers...

104
Page 107 / 108
Tables
Tables
Table 1: Related documents .......................................... 3 Table 27: Weights of assemblies [kg] ........................ 52
Table 2: Weights A200-L with filter silencer.............. 8 Table 28: Weight of wall insert [kg]............................ 52
Table 3: General information about fastening the Table 29: Tightening torques (filter silencer screws)..
turbocharger .................................................................. 11 57
Table 4: Tightening torques (foot screws) .............. 12 Table 30: Admissible axial clearance A ...................... 64
Table 5: Tightening angle (foot screws)................... 12 Table 31: Maximum admissible loosening torque
(51087) ............................................................................. 67
Table 6: Lubricating oil pressure, oil inlet ................ 16
Table 32: Maximum admissible loosening torque
Table 7: Lubricating oil temperature at the inlet .... 16 (51087) ............................................................................. 70
Table 8: Lubricating oil temperature at the outlet. 17 Table 33: Tightening torque (56014) ......................... 73
Table 9: Tightening torques (86505)........................ 20 Table 34: Tightening torque (61009) ......................... 74
Table 10: Expected replacement intervals for tur- Table 35: Tightening torque (51087).......................... 75
bocharger parts............................................................. 27
Table 36: Tightening torque (56014) ......................... 78
Table 11: Recommended replacement intervals for
turbocharger parts ....................................................... 27 Table 37: Tightening torque (61009) ......................... 79
Page 108 / 108
Table 12: Volume of water per cleaning process.... 38 Table 38: Tightening torque (51087) ......................... 80
Table 13: Tightening torques (81125) ....................... 38 Table 39: Admissible axial clearance A ...................... 81
Table 14: Cleaning parameters .................................. 42 Table 40: Tightening torque (77015) ......................... 82
Table 15: Malfunctions when starting – Delayed Table 41: Tightening torque (72011) .......................... 84
start-up .......................................................................... 44
Table 16: Malfunctions when starting – Vibrations 44
Table 17: Malfunctions when starting – Rubbing of
rotating parts................................................................ 44 Table 44: Overview of tightening torques................ 89
Table 18: Malfunctions during operation – Lubricat- Table 45: Tightening torque, insulation.................... 89

ing oil pressure too low............................................... 45
Table 46: Bypass procedure ........................................ 91
Table 19: Malfunctions during operation – Drop in
speed ............................................................................. 45 Table 47: Tightening torque B1, B2, B3 ......................... 93
Table 20: Malfunctions during operation – Exhaust Table 48: Required washers (01) ................................ 94
gas temperature too high .......................................... 46
Table 49: Tightening torque (57005)......................... 94
Table 21: Malfunctions during operation – Charge air
Table 50: Customer spare part set (97070) ........... 100
pressure too low........................................................... 46
Table 51: Customer spare part set (97071)............. 101
Table 22: Malfunctions during operation – Charge air
pressure too high ......................................................... 47 Table 52: Turbocharger with part numbers ........... 103
Table 23: Surging of the turbocharger..................... 47 Table 53: Cartridge group with part numbers....... 105
Table 24: Malfunctions when stopping – Runout
noises.............................................................................. 48
Table 25: Malfunctions when stopping – Shortened

runout time.................................................................... 48
Table 26: Malfunctions of the speed measurement

system ............................................................................ 49

Operation Manual: XAC20243 English

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Operation Manual

3 Safety data sheet XAC20243

4 Product description HZTL4036_EN_N

1.1 Purpose of the manual

Fig. 1: Serial number (01) on the rating plate

Availability of the Operation Manual

1.2 Symbols, definitions

1. Indicates a numbered action step.

Definition of mandatory signs

Definition of Caution / Warning

ABB Turbo Systems

Official service stations of ABB Turbo Systems

Pictogram Meaning Pictogram Meaning

Tighten over specified tighten- Measure

Apply other paste in accord- Dispose of in an environmentally

Table 1: Definition of pictograms

1.3 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts for up to 6 months

Fig. 2: Volatile Corrosion Inhibitor (VCI)

Wear safety gloves to protect against mechanical hazards.

Every 6 months, the following mothballing measures are required:

Long-term storage of replacement turbochargers or spare parts

Fig. 3: Package with hygrometer

Every 6 months, the following measures are required:

Unpackaging replacement turbochargers or spare parts

1.4 Contact information

ABB Turbo Systems Ltd

1.3 Definition of mandatory signs

Table 1: Personal protective equipment to be worn at all times

To be worn specific to the respective task

Safety gloves to protect Respiratory mask to protect

1.4 Definition of safety instructions

1.5 Intended use

Use on internal combustion engines in general

State of the art

1.6 Warning plates on the turbocharger

Fig. 1: Warning plate

1.7 Turbocharger rating plate

Fig. 2: Rating plate

02 Turbocharger operating limits during operation

Recommended replacement intervals of turbocharger components

Explanations regarding the rating plate

Locations of the rating plates

1.8 Periodic check of the pressure vessels

1.9 Lifting of loads

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

Fig. 3: Attachment of loads on the crane hook

Fig. 4: Attachment angle

u Use a suitable edge guard if there are sharp edges.

u Use assembly devices only for the described applications.

1.10 Prerequisites for operation and maintenance

Responsibility of the operating company

Modifications to the turbocharger

1.11 Hazards during operation and maintenance

Wear ear protection.

Hazards due to hot surfaces

Wear safety gloves to protect against thermal hazards.

Wear safety gloves to protect against thermal hazards.

Hazards due to rotating parts

Wear safety gloves to protect against mechanical hazards.

Hazards due to electrical installations (if present)

1.12 Safe operation